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Established as per the Section 2(f) of the UGC Act, 1956
Approved by AICTE, COA and BCI, New Delhi
Electrical Power Utilization
Course Code :B19EE4051
School of Electrical and Electronics Engineering,
REVA University
Latha N,
Ass istant Professor
A Y : 2 0 2 0 - 2 0 2 1
COURSE CONTENTS
UNIT – 2a: Introduction to Electric and Hybrid Vehicles Total duration = 12 Hours
Configuration and performance of electrical vehicles
Traction motor characteristics, tractive effort, transmission requirement
Vehicle performance and energy consumption
.
Frenchman
Gustave Trouvé
First electric
vehicle (1881)
ELECTRIC AND HYBRID VEHICLES
Tricycle
0.1 hp DC motor
Lead–acid batteries
ELECTRIC AND HYBRID VEHICLES
ELECTRIC AND HYBRID VEHICLES
•No emission
•High efficiency
•Very robust & less maintenance
•Quiet and smooth operation
•Excellent torque and output characteristics
•Regenerative braking
Advantages of EV over ICEV
Advantages of EV over ICEV
ELECTRIC AND HYBRID VEHICLES
•Limited range
•Charging time
•Electric charging stations is sparse
Disadvantages of EV over ICEV
Disadvantages of EV over ICEV
ELECTRIC AND HYBRID VEHICLES
ICEV EV
Gasoline tank
IC
Batteries
Electric Motor
How EV is made from ICEV?
ELECTRIC AND HYBRID VEHICLES
Modern EV in place of primary EV
ELECTRIC AND HYBRID VEHICLES
Drive Train
Electric
propulsion
system
Energy source
sub system
The auxiliary
sub system
Modern EV in place of primary EV
ELECTRIC AND HYBRID VEHICLES
Electric propulsion
system
Vehicle controller
Power electronic
converter
Electric motor
Mechanical
Transmission
Driving wheels
1. Electric propulsion system
ELECTRIC AND HYBRID VEHICLES
Energy Source Sub
System
Energy Source
The Energy Management
Unit
The Energy Refueling Unit
2. Energy source sub system
ELECTRIC AND HYBRID VEHICLES
3. The auxiliary sub system
The auxiliary sub
system
Power steering unit
The hotel climate
Control unit
The auxiliary supply
unit
ELECTRIC AND HYBRID VEHICLES
1. Electric propulsion system
Power electronic converter regulates the power flow between the electric
motor and energy source
Power electronic converter regulates the power flow between the electric
motor and energy source
Control inputs from the accelerator and brake pedals to vehicle controller
Control signals from vehicle controller to electronic power converter
ELECTRIC AND HYBRID VEHICLES
2. Energy source sub system
Energy management unit (EMU) cooperates with the
vehicle controller to control the regenerative braking and
its energy recovery
EMU also works with the energy refueling unit to control
the refueling unit and to monitor the usability of the
energy source
ELECTRIC AND HYBRID VEHICLES
3. The auxiliary sub system
Provides the necessary power with different voltage
levels for all the EV auxiliaries (climate control
and power steering unit)
ELECTRIC AND HYBRID VEHICLES
EV configurations
C : Clutch
D : Differential
FG : Fixed Gearing
GB : Gearbox
M : Electric Motor
ELECTRIC AND HYBRID VEHICLES
EV configurations
The clutch is used to connect or disconnect the
power of electric motor from the driven wheels
The differential is a mechanical device (usually a set of planetary gears) which
enables both sides to be driven at different speeds when the vehicle runs along
a curved path
The gear box provides a set of gear ratios to
The gear box provides a set of gear ratios to
modify the speed-power (torque) profile to match
the load requirement
ELECTRIC AND HYBRID VEHICLES
EV configurations
An electric motor that has a constant power in a long
range, a fixed gearing can replace the multispeed
gearbox and reduce the need of a clutch
Not only reduces the size and weight of the mechanical transmission, it also simplifies
the drive train control because gear shifting is not required
ELECTRIC AND HYBRID VEHICLES
EV configurations
M,FG and D can be further integrated into a single
assembly while both axles point at both driving
wheels
The whole drive train is further simplified and compacted
ELECTRIC AND HYBRID VEHICLES
EV configurations
D is replaced by using two traction motors
Each of them drives one side wheel and operates at a different speed when
the vehicle is running along a curved path
ELECTRIC AND HYBRID VEHICLES
EV configurations
The drive train and M can be placed inside a
wheel
A thin planetary gear set may be employed to reduce the motor speed
and enhance the motor torque
ELECTRIC AND HYBRID VEHICLES
EV configurations
Mechanical gearing is avoided by connecting a
low speed motor directly to the driving
wheels
The speed control of motor is the speed control of driving
wheel
But this arrangement requires a motor having a higher torque
ELECTRIC AND HYBRID VEHICLES
Performance of EVs
Vehicle’s driving
performance
Acceleration
time
Maximum
speed
Gradeability
Proper motor power rating and transmission parameters are the primary
considerations to meet the performance specification
The design of all these parameters depends on the speed-power (torque)
characteristics of the traction motor
ELECTRIC AND HYBRID VEHICLES
Traction motor characteristics
Variable speed motor
characteristics
ELECTRIC AND HYBRID VEHICLES
Traction motor characteristics
The characteristics is usually represented by a speed ratio x, defined as the ratio of
its maximum speed to its base speed
Low speed region
(less than the base speed)
motor has a constant
torque
High-speed region
(Higher than the base speed)
motor has a constant
power
ELECTRIC AND HYBRID VEHICLES
Traction motor characteristics
In low-speed operations, voltage supply to the motor increases with the increase
of the speed through the electronic converter while the flux is kept constant
After the base speed, the motor voltage is kept constant and the flux is
weakened, dropping hyperbolically with increasing speed. Hence, its torque also
drops hyperbolically with increasing speed
At the point of base speed, the voltage of the motor reaches the source voltage
ELECTRIC AND HYBRID VEHICLES
Traction motor characteristics
Speed- Torque
characteristics different
speed ratios x (x=2,4,6)
ELECTRIC AND HYBRID VEHICLES
Traction motor characteristics
With a long constant power region, the maximum torque of the motor can be
significantly increased, and hence vehicle acceleration and gradeability
performance can be improved and the transmission can be simplified
ELECTRIC AND HYBRID VEHICLES
Vehicle performance
Vehicle’s driving
performance
Acceleration
time
Maximum speed Gradeability
ELECTRIC AND HYBRID VEHICLES
Vehicle performance
Acceleration time
Acceleration performance of a vehicle is evaluated by the time used to
accelerate the vehicle from a low speed to a higher speed (100km/h for
passenger cars)
For passenger cars, acceleration performance is more important than max.
cruising speed and gradeability, since power rating of motor drive
depends on acceleration performance
ELECTRIC AND HYBRID VEHICLES
Vehicle performance
Maximum speed
The maximum speed of a vehicle can be easily found by the intersection point of the
tractive effort curve with the resistance curve
ELECTRIC AND HYBRID VEHICLES
Vehicle performance
Gradeability
It is defined as the highest grade a vehicle can ascend maintaining a particular speed
The maximum grade that a fully laden vehicle combination is capable to maintain the
forward motion on an uphill road at a certain constant speed at a certain friction level
OR
It is determined by the net tractive effort of the vehicle
The gradeability at mid and high speeds is smaller than at low speed
ELECTRIC AND HYBRID VEHICLES
Tractive effort
𝒕
𝒎 𝒈 𝟎 𝒕
𝒅
𝒎 𝒅
𝒈 𝟎
The tractive effort developed by a traction motor on driven wheels
And the vehicle speed
Tm and are the motor torque output
Nm speed in rpm
ig is the gear ratio of transmission
i0 is the gear ratio of final drive
ηt is the efficiency of the whole driveline from the motor to the driven wheels
and rd is the radius of the drive wheels
ELECTRIC AND HYBRID VEHICLES
The use of a multigear or single gear depends mostly on the motor speed-torque
characteristics
At a given rated motor power, if the motor has a long constant power region, a
single gear transmission would be sufficient for a high tractive effort at low
speeds, otherwise a multigear (more than two gears) transmission has to be used
Transmission requirement
ELECTRIC AND HYBRID VEHICLES
Transmission requirement
x=2, 3 gears, 3 speed
regions
ELECTRIC AND HYBRID VEHICLES
Transmission requirement
x=4, 2 gears, 2 speed
regions
ELECTRIC AND HYBRID VEHICLES
Transmission requirement
x=6, 1 gear, 1 speed
regions
ELECTRIC AND HYBRID VEHICLES
Energy consumption
Energy consumption
ELECTRIC AND HYBRID VEHICLES
The energy consumption is an integration of the power output at the battery
The energy consumption is an integration of the power output at the battery
terminals
Energy consumption
Energy consumption
For propelling, the battery power output is equal to the resistance power
and power losses in transmission and motor drive, including power losses in
the electronics
The efficiency of a traction motor varies its operating points on the speed-
time curve (speed-power) plane, where the most efficient operating area exists
ELECTRIC AND HYBRID VEHICLES
The architecture of a hybrid vehicle is defined as the connection between the
components that define the energy flow routes and control ports
HYBRID VEHICLES
ELECTRIC AND HYBRID VEHICLES
Classification of Hybrid vehicles
Classification of Hybrid vehicles
HEVS
Series hybrid
Parallel hybrid
Series–parallel hybrid
Complex hybrid
ELECTRIC AND HYBRID VEHICLES
HYBRID VEHICLES
HYBRID VEHICLES
ELECTRIC AND HYBRID VEHICLES
HYBRID VEHICLES
HYBRID VEHICLES
ELECTRIC AND HYBRID VEHICLES
HYBRID VEHICLES
HYBRID VEHICLES
Configuration of a series hybrid electric drive train
Configuration of a series hybrid electric drive train
ELECTRIC AND HYBRID VEHICLES
Operation modes
Pure electric mode
Pure engine mode
Hybrid mode
Engine traction and battery charging mode
Regenerative braking mode
Battery charging mode
Hybrid battery charging mode
Operation modes of a series hybrid electric drive train
ELECTRIC AND HYBRID VEHICLES
Pure electric mode
Operation modes of a series hybrid electric drive train
The engine is turned off and the vehicle is propelled only by the
The engine is turned off and the vehicle is propelled only by the
batteries
Pure engine mode
 The vehicle traction power only comes from the engine-generator, while the
batteries neither supply nor draw any power from the drive train.
 The electric machines serve as an electric transmission from the engine to
the driven wheels
ELECTRIC AND HYBRID VEHICLES
Operation modes of a series hybrid electric drive train
Hybrid mode
The traction power is drawn from both the engine generator and the batteries
Engine traction and battery charging mode
The engine-generator supplies power to charge the batteries and to propel
The engine-generator supplies power to charge the batteries and to propel
the vehicle
ELECTRIC AND HYBRID VEHICLES
Operation modes of a series hybrid electric drive train
Regenerative braking mode
Battery charging mode
 The engine-generator is turned off and the traction motor is operated as a
generator
 The power generated is used to charge the batteries
The traction motor receives no power and the engine-generator charges the
batteries
ELECTRIC AND HYBRID VEHICLES
Operation modes of a series hybrid electric drive train
Hybrid battery charging mode
Both the engine-generator and the traction motor operate as generators to
charge the batteries
Operation modes of a series hybrid electric drive train
ELECTRIC AND HYBRID VEHICLES
Series hybrid electric drive train
Advantages
Advantages
Because electric motors have near-ideal torque–speed characteristics, they
Because electric motors have near-ideal torque–speed characteristics, they
do not need multigear transmissions. Therefore, their construction is
greatly simplified and the cost is reduced
Simple control strategies may be used as a result of the mechanical
decoupling provided by the electrical transmission
ELECTRIC AND HYBRID VEHICLES
Series hybrid electric drive train
Disadvantages
Disadvantages
in
 The energy from the engine is converted twice (mechanical to electrical in
the generator and electrical to mechanical in the traction motor)
 The inefficiencies of the generator and traction motor add up and the
losses may be significant
The generator adds additional weight and cost
The traction motor must be sized to meet maximum requirements since it is
the only power plant propelling the vehicle
Thank You
Name : Latha N
Department: School of Electrical and Electronics Engineering
Contact : Email ID: latha.n@reva.edu.in
Mobile No. : 9743994095
Established as per the Section 2(f) of the UGC Act, 1956
Approved by AICTE, COA and BCI, New Delhi
Electrical Power Utilization
Course Code :B19EE4051
School of Electrical and Electronics Engineering,
REVA University
Latha N,
Ass istant Professor
A Y : 2 0 2 0 - 2 0 2 1
COURSE CONTENTS
UNIT – 2b: Electrolytic process Total duration = 12 Hours
Fundamental principles
Extraction, refining of metals and electroplating
Factors affecting electro deposition process
Power supply for electrolytic process
Numerical
ELECTROLYTIC PROCESS
The process in
which electrical
energy is used
to produce
chemical
changes
.
.
ELECTROLYTIC PROCESS
Copper
Zinc
Aluminium
Magnesium
ELECTROLYTIC PROCESS
Gold
Silver
Copper
Nickel
ELECTROLYTIC PROCESS
Manufacturing
of chemicals
Caustic soda
Potassium permanganate
Chlorine
ELECTROLYTIC PROCESS
Electrotyping
ELECTROLYTIC PROCESS
Chemical
Metallurgical
ELECTROLYTIC PROCESS
Electrolysis
 Electrolysis, process by which electric current is passed through
a substance to effect a chemical change
 The chemical change is one in which the substance loses or
gains an electron (oxidation or reduction)
ELECTROLYTIC PROCESS
Electrolysis
CuSO4
Cu++
SO4
--
𝟒 𝟐 𝟐 𝟒 𝟐
𝟐 𝟒 𝟒 𝟐
ELECTROLYTIC PROCESS
Faraday’s laws of Electrolysis
The mass of the substance liberated during electrolysis is directly proportional to
quantity of electricity flowing through the electrolyte
First Law
First Law
Where, m = mass of the substance liberated in kg
Z = a constant know as the electro-chemical
equivalent of the substance in Kg/C
I = current flowing in amperes
t = time for which flows in seconds
ELECTROLYTIC PROCESS
Faraday’s laws of Electrolysis
First Law
First Law
The electrochemical equivalent Z of a substance is defined as the amount of the
substance deposited , when a current of 1A flows through the electrolyte for 1
second
If, And
Then,
Unit is in kilogram per coulomb (kg/C)
ELECTROLYTIC PROCESS
Faraday’s laws of Electrolysis
When same quantity of electricity is passed through several electrolytes, the mass
of the substances liberated are proportional to their respective chemical
equivalents or equivalent weights
Second Law
Second Law
ELECTROLYTIC PROCESS
Definitions
Electrochemical equivalent (Z)
ECE of a substance is the mass of it liberated in a process of electrolysis by the
passage of unit quantity of electricity, i.e. by unit current (ampere) for unit time
(second)
The SI unit of ECE (Z), is the kg/Coulomb
Atomic weight
Atomic weight of an element is a number, which is the average of the masses of
its various isotopes (protons=electrons, no. of neutrons different)
ELECTROLYTIC PROCESS
Definitions
Formula weight
Formula weight of a chemical entity (atom, radical, molecule, ion) is the sum of
the atomic weights of its constituents
Example:
The formula weight of water (H2O) is two times
the atomic weight of hydrogen plus one times
the atomic weight of oxygen
Numerically, this is
(2×1.00797)+(1×15.9994)
= 2.01594+15.9994=18.01534
ELECTROLYTIC PROCESS
Definitions
Valency
The Valency of an atom or radical (a group of atoms) is the no. of hydrogen
atoms with which it will react chemically
Valency is always an integer (i.e. 1,2,3..) but for a given atom or radical, it
can have different values in different chemical reactions
Example:
Valency of Aluminium is 3
ELECTROLYTIC PROCESS
Definitions
Equivalent weight
It is defined as the mass of an element/compound/ion which combines or
displaces 1 part of hydrogen or 8 parts of oxygen or 35.5 parts of chlorine
by mass
Example:
Atomic weight of Silver is 107.88 and Valency is 1
Then , Equivalent weight is 107.88
ELECTROLYTIC PROCESS
ELECTROLYTIC PROCESS
Current efficiency
Current efficiency is defined as “ The ratio of the actual quantity of
substances liberated to the theoretical quantity”
Definitions
It is usually between 90 to 98%, for Chromium plating only about 12 to 15%
ELECTROLYTIC PROCESS
Energy efficiency
Energy efficiency is defined as ratio of the theoretical energy required for
depositing a certain quantity of the substance to the actual value of the energy
required
Definitions
ELECTROLYTIC PROCESS
Electrode Potential
A potential difference exists between the anode and electrolyte and also
between cathode and electrolyte, this potential difference is called
electrode potential
Depends on temperature and concentration of electrolyte
ELECTROLYTIC PROCESS
Calculation of current required
From the ECE(kg/C) it is possible to calculate the theoretical value of current
required to deposit any given quantity of metal or alternatively the amount of
metal which should theoretically be deposited by a given current
A sheet of iron having a total surface area of 0.36m2 is to be electroplated
with copper to a thickness of 0.0254mm.Estimate the time required for the
process? The iron will be made cathode and immersed, together with an
anode of pure copper, in a solution of copper sulphate. Given density of
copper as 8.96e+03kg/m3 , ECE of copper as Z=32.9e-08 kg/C, current
density is 330A/m2
ELECTROLYTIC PROCESS
Numerical - 1
 Surface area = a = 0.36m2
 Thickness = t = 0.0254mm
 Density of copper = D = 8.96e+03kg/m3
 ECE of copper = Z = 32.9e-08 kg/C
 Current density = δ = 330A/m2
ELECTROLYTIC PROCESS
Data Given:
To find:
Time required=T=?
Numerical - 1
ELECTROLYTIC PROCESS
Solution - 1
Mass of the copper deposited = 9.144 x 10-6 m3 x 8.96e+03 kg/m3
Volume of the Iron Sheet = Surface Area of the Iron sheet x Thickness of sheet
Volume of the Iron Sheet = 9.144 x 10-6 m3
Volume of the Iron Sheet = 0.36m2 x 0.0254mm
Mass of the copper deposited = Volume of the Iron Sheet x Density
Volume of the Iron Sheet = 0.36 x 0.0254 x 10-3
AH = 69.233 kg
Mass of the copper deposited = 0.081930 kg = 0.082kg
ELECTROLYTIC PROCESS
Solution - 1
Current = I = 0.36m2 x 330A/m2
T = 0.585 Hrs
Current = I = Surface Area x Current Density
Current = I = 118.8 A
Calculate the Ah required to deposit a coating of silver 0.1mm thick on a
sphere of 10cm radius. Assume ECE of silver = 0.001118 g/C and density
of silver to be 10.5 g/cm3. Assume that the energy efficiency is 95%.
ELECTROLYTIC PROCESS
Numerical - 2
 Thickness = t = 0.1mm
 Radius of sphere = r = 10cm
 Density of silver = D = 10.5 g/cm3
 ECE of silver = Z = 0.001118 g/C
 energy efficiency = 95%
ELECTROLYTIC PROCESS
Data Given:
To find:
AH required = ?
Numerical - 2
ELECTROLYTIC PROCESS
Solution - 2
Volume = Surface Area of Sphere x Thickness
Volume = 12.5664 cm3
Mass of the silver deposited = Volume x Density
Surface Area of Sphere = 4𝜋𝑟
Surface Area of Sphere = 1256.64𝑐𝑚
Surface Area of Sphere = 4𝜋 ∗ 10
Volume = 1256.64𝑐𝑚 x 0.1 x 10
Mass of the silver deposited = 12.5664 cm3 x 10.5 g/cm3
Mass of the silver deposited = 131.94 g
ELECTROLYTIC PROCESS
Solution - 2
AH = 32.78 g Theoretical Value of AH
Actual AH = 34.50 g
If 96500C of electricity liberate 1g equivalent of any substance, how long
will it take for a current of 0.15A to deposit 20mg of Cu from a solution of
copper sulphate? Chemical equivalent of Cu is to be taken as 32.
ELECTROLYTIC PROCESS
Numerical - 3
 Current = I = 0.15A
 Mass of copper deposited = 20mg
 ECE of copper = Z = 32/96500 g/C
ELECTROLYTIC PROCESS
Data Given:
To find:
Time required = T = ?
Numerical - 3
ELECTROLYTIC PROCESS
Solution - 3
AH = 0.01675
T = 402s
T = 0.11168Hrs
A rectangular plate 20 x 10cm is to be coated with Nickel with a layer of
0.2mm thickness. Determine the quantity of electricity in Ah and time
taken for the process. Current density is 190A/m2 and current efficiency is
90%. Specific gravity (density) of nickel is 8.9g/m3. ECE of Nickel =
0.0010954kg/Ah
ELECTROLYTIC PROCESS
Numerical - 4
A 20cm long portion of a circular shaft 10cm diameter is to be coated with
a layer of 15mm Nickel. Determine the quantity of electricity in Ah and time
taken for the process. Assume a current density of 195 A/m2 and current
efficiency of 92%, Specific gravity (density) of Nickel is 8.9g/m3, ECE of
Nickel = 1.0954kg/1000Ah
ELECTROLYTIC PROCESS
Numerical - 5
The to
The worn out part of a circular shaft 0.15m in diameter and 0.3m long is to
be repaired by depositing on it 1.6mm of Nickel by electro-deposition
process. Estimate the quantity of electricity required and the time taken, if
the current density is 215A/m2. The energy efficiency of the process may be
taken as 95%. The density of Nickel is 8.9e+03kg/m3 and ECE of Nickel is
30.349e-08kg/C
ELECTROLYTIC PROCESS
Numerical - 6
Nickel coating of 1mm thickness is to be built on a cylindrical surface 15cm
diameter and 20cm long in 1 ½ Hrs. Calculate the electrical energy needed
if ECE of nickel is 0.3043 mg/C. Specific gravity (Density) =8.9g/m3 and
voltage used in electroplating is 10V.
ELECTROLYTIC PROCESS
Numerical - 7
Estimate the current required to produce 10g of caustic soda in 5min from a
solution of sodium chloride given that ECE of sodium is 0.0002388g/C and
atomic weights of sodium=23, Oxygen=16 and Hydrogen=1
ELECTROLYTIC PROCESS
Numerical - 8
A weighed copper plate is made as cathode in a copper sulphate
voltammeter (electrolytic cell). At the end of two hours a weight of 50g was
deposited on it. The current during the operation time was kept constant
and the ammeter indicated 20A. Did the ammeter read correctly; if not
what is the %age error?. Given atomic weight of copper=63.5; Hydrogen
= 1; Silver = 108 and ECE of Silver=0.001118g/C, Valency of Copper=2,
Valency of Silver=1
ELECTROLYTIC PROCESS
Numerical - 9
ELECTROLYTIC PROCESS
Extraction of metals
Extraction of metals
Ore is treated with
strong acid
Ore is available in
molten state
ELECTROLYTIC PROCESS
Extraction of metals
Metal Treatment of ore Solution
Consumption
kwh/t (approx.)
Aluminium -
Fused cryolyte (combustible matter
for firing mines)
20,000-25,000
Copper
Roasted and leached (to
moisten) with sulphuric
acid
Copper sulphate 2000-2500
Magnesium -
Fused magnesium chloride or
carnallite
17,000-20,000
Sodium -
Fused sodium hydrate or sodium
nitrate and sodium chloride
10,000-20,000
Zinc Leached with sulphuric
acid
Zinc chloride and zinc sulphate 3000-5000
ELECTROLYTIC PROCESS
Extraction of Zinc
The ore, consisting largely of zinc oxide, treated with strong sulphuric acid, roasted
and passed through various chemical processes to precipitate cadmium, copper
and any other impurities; the resulting zinc sulphate solution is passed to the
electrolytic cells
The electrolytic cells consists of large lead-lined wooden boxes, each containing a
no. of aluminum cathodes and lead anodes and carrying a current of several
hundred and thousand Amperes, according to the size
ELECTROLYTIC PROCESS
Extraction of Zinc
The current density on the cathodes is about 1100A/sq. m
The potential drop in each cell is about 3.5V, so that 100 or 150 of them in
series
The zinc is deposited on the cathodes, which are removed once or twice a day
for stripping (To peel)
The energy consumed is of the order 3000 to 5000kWh per tonne
ELECTROLYTIC PROCESS
Extraction of Aluminium
An example of the fused electrolyte process is the extraction of aluminium from
its ores, bauxite and cryolite
The bauxite is first treated chemically to reduce it to aluminium oxide and this is
then dissolved in fused cryolite and electrolyzed
The furnace in which the fusion and electrolysis take place consists of a shallow
rectangular bath lined with carbon
ELECTROLYTIC PROCESS
Extraction of Aluminium
Carbon anodes project downwards into the bath and the bottom of the bath
forms the cathode
The high temperature (1000 degree) necessary to keep the ores in a fused state
is maintained by the Ohmic losses of the current passing through the electrodes
and electrolyte
ELECTROLYTIC PROCESS
Extraction of Aluminium
A furnace having an area of 13.6 sq.mt will require a pressure of 5 or 6V and a
current of 40,000A
Aluminium is deposited at the cathode and settles at the bottom of the bath, from
which it is tapped off as required
ELECTROLYTIC PROCESS
Refining of metals
Highly concentrated mixture of metals is subjected to electrolysis for recovering of
metal in its purest form
Recover precious metals like gold, silver, bismuth
ELECTROLYTIC PROCESS
Refining of metals
Metal Solution Consumption
kWh/tonne
Copper Copper sulphate 150-300
Gold Chloride of gold 300-350
Iron Iron ammonium sulphate 1000-1500
Lead Lead fluosilicate 100-120
Nickel Nickel-chloride and
sulphate
2500-4000
Silver Nitric acid and silver
nitrate
400-420
ELECTROLYTIC PROCESS
Refining of Copper
Copper is usually mined from its coal known as blister copper. It is about 98 to 99
per cent pure. Electro-refining process can easily make it 99.95% pure which makes it
a good product
A block of impure copper is taken as an anode or positive electrode
Copper sulphate which is acidified with sulphuric acid is used as a graphite-coated
electrolyte along with pure copper tubes, as a cathode or negative electrode
ELECTROLYTIC PROCESS
Refining of Copper
In this phase of electrolysis copper sulfate divides into a positive ion of copper (Cu++)
and a negative ion of sulphate (SO4—)
The positive copper ion (Cu++) or cations travel towards the negative electrode
made of pure copper where it absorbs the electrons from the cathode
Cu atom is deposited on the cathode’s graphite layer
ELECTROLYTIC PROCESS
Electro deposition
Electrolytic process in which one metal is coated over another metal or non metal
in its pure form
This process is used in electro-plating, electro-forming, electro-typing, electro-
facing, electro-metallization , electro-deposition of rubber
ELECTROLYTIC PROCESS
Electro deposition
Nature of electrolyte
Current density
Temperature
Conductivity
Electrolytic concentration
Additional agents
Throwing power
Polarization
Factors governing electro-
deposition process
ELECTROLYTIC PROCESS
Electro deposition
Nature of electrolyte
 The electrolyte from which complex ions can be obtained, such as
cyanides, provides a smooth deposit
ELECTROLYTIC PROCESS
Electro deposition
Current density
 The deposit of metal will be uniform and fine-grained if the current
density is used at rate higher than that at which the nuclei are formed
 The deposit will be strong and porous if the rate of formation of nuclei is
very high due to very high current density
ELECTROLYTIC PROCESS
Electro deposition
Temperature
 A low temperature of the solution favours formation of small crystals
of metal; and at high temperature, large crystals
ELECTROLYTIC PROCESS
Electro deposition
Conductivity
 The solution of good conductivity is important from the standpoint
of view of economy in power consumption and also because it
reduces the tendency to form trees and rough deposits
ELECTROLYTIC PROCESS
Electro deposition
Electrolytic Concentration
 Higher current density, which is necessary to obtain uniform and
fine-grain deposit, can be achieved by increasing the concentration
of the electrolyte
ELECTROLYTIC PROCESS
Electro deposition
Additional Agents
 The addition of acids or other substances to the electrolyte reduces
its resistance
 additional agents are glue, gums, dextrose, dextrin, gelatin, agar,
alkaloids, albumen, phenol, glycerin, sugar, glucose, rubber
influence nature of deposit
 The crystal nuclei absorb the additional agent added in the
electrolyte
 This prevents it to have large growth and thus deposition will be
fine-grained
ELECTROLYTIC PROCESS
Electro deposition
Throwing power
 It is the ability of electrolyte to produce uniform deposit on an
article of irregular shape
 Due to unequal distance, the resistance of the current path
through the electrolyte for various portions of the cathode will be
different
 But the potential difference between the anode and any point on
the cathode will be the same
 And the result will be that the current density will be more on the
portion nearer to anode and it will cause uneven deposit of the
metal
ELECTROLYTIC PROCESS
Electro deposition
Polarization
 The rate of deposition of metal increases with the increase in
electroplating current density up to a certain limit
 after which electrolyte surrounding the base metal becomes so much
depleted that the increase in current density does not cause increase
rate of deposition
 Increase in current density beyond this limit causes electrolysis of water
and hydrogen liberation on the cathode
 This hydrogen evolved on the cathode blankets the base metal which
reduces the rate of metal deposition
ELECTROLYTIC PROCESS
Electro Plating
Electroplating is electrolytic process in which superior or noble metal is
deposited on an inferior or base metal
Purpose of Electroplating
To protect the metals against corrosion
To give reflecting properties to the
reflectors
To give a shiny appearance to articles
To repair the worn-out materials
ELECTROLYTIC PROCESS
Electro Plating
 Electrolytic deposits are crystalline in nature and the
crystals deposited must be very fine, coherent and
uniform deposition
 Proper current density value
 Proper temperature level
Example:
For 1000 CC solution,
150-200gms of copper sulphate
25 – 35 gms of sulphuric acid
Current density 150 – 400A/m2
Temperature 25 – 500C
ELECTROLYTIC PROCESS
Power supply for electrolytic process
Power supply required for electrolytic process is low voltage DC supply
For electro-deposition a power supply of 10 to 12 volts which can give 100
to 200 amperes is adequate
Power Supply
Using a Motor-Generator Set
Using a metal Oxide Rectifier
ELECTROLYTIC PROCESS
Power supply for electrolytic process
Using a Motor-Generator Set
 The motor is an ordinary three phase induction motor and the
generator is a heavy current, low voltage DC generator
 The generator should preferably be separately excited
 DC voltage can be controlled by controlling the excitation of the
generator
ELECTROLYTIC PROCESS
Power supply for electrolytic process
Using a metal Oxide Rectifier
 Better efficiency at low voltages especially at low loads, occupies
less space, has low maintenance cost
 Recently the solid state rectifying devices employing germanium
and silicon diodes have been developed for use
Thank You
Name : Latha N
Department: School of Electrical and Electronics Engineering
Contact : Email ID: latha.n@reva.edu.in
Mobile No. : 9743994095

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Electric traction

  • 1. Established as per the Section 2(f) of the UGC Act, 1956 Approved by AICTE, COA and BCI, New Delhi Electrical Power Utilization Course Code :B19EE4051 School of Electrical and Electronics Engineering, REVA University Latha N, Ass istant Professor A Y : 2 0 2 0 - 2 0 2 1
  • 2. COURSE CONTENTS UNIT – 2a: Introduction to Electric and Hybrid Vehicles Total duration = 12 Hours Configuration and performance of electrical vehicles Traction motor characteristics, tractive effort, transmission requirement Vehicle performance and energy consumption .
  • 3. Frenchman Gustave Trouvé First electric vehicle (1881) ELECTRIC AND HYBRID VEHICLES Tricycle 0.1 hp DC motor Lead–acid batteries
  • 5. ELECTRIC AND HYBRID VEHICLES •No emission •High efficiency •Very robust & less maintenance •Quiet and smooth operation •Excellent torque and output characteristics •Regenerative braking Advantages of EV over ICEV Advantages of EV over ICEV
  • 6. ELECTRIC AND HYBRID VEHICLES •Limited range •Charging time •Electric charging stations is sparse Disadvantages of EV over ICEV Disadvantages of EV over ICEV
  • 7. ELECTRIC AND HYBRID VEHICLES ICEV EV Gasoline tank IC Batteries Electric Motor How EV is made from ICEV?
  • 8. ELECTRIC AND HYBRID VEHICLES Modern EV in place of primary EV
  • 9. ELECTRIC AND HYBRID VEHICLES Drive Train Electric propulsion system Energy source sub system The auxiliary sub system Modern EV in place of primary EV
  • 10. ELECTRIC AND HYBRID VEHICLES Electric propulsion system Vehicle controller Power electronic converter Electric motor Mechanical Transmission Driving wheels 1. Electric propulsion system
  • 11. ELECTRIC AND HYBRID VEHICLES Energy Source Sub System Energy Source The Energy Management Unit The Energy Refueling Unit 2. Energy source sub system
  • 12. ELECTRIC AND HYBRID VEHICLES 3. The auxiliary sub system The auxiliary sub system Power steering unit The hotel climate Control unit The auxiliary supply unit
  • 13. ELECTRIC AND HYBRID VEHICLES 1. Electric propulsion system Power electronic converter regulates the power flow between the electric motor and energy source Power electronic converter regulates the power flow between the electric motor and energy source Control inputs from the accelerator and brake pedals to vehicle controller Control signals from vehicle controller to electronic power converter
  • 14. ELECTRIC AND HYBRID VEHICLES 2. Energy source sub system Energy management unit (EMU) cooperates with the vehicle controller to control the regenerative braking and its energy recovery EMU also works with the energy refueling unit to control the refueling unit and to monitor the usability of the energy source
  • 15. ELECTRIC AND HYBRID VEHICLES 3. The auxiliary sub system Provides the necessary power with different voltage levels for all the EV auxiliaries (climate control and power steering unit)
  • 16. ELECTRIC AND HYBRID VEHICLES EV configurations C : Clutch D : Differential FG : Fixed Gearing GB : Gearbox M : Electric Motor
  • 17. ELECTRIC AND HYBRID VEHICLES EV configurations The clutch is used to connect or disconnect the power of electric motor from the driven wheels The differential is a mechanical device (usually a set of planetary gears) which enables both sides to be driven at different speeds when the vehicle runs along a curved path The gear box provides a set of gear ratios to The gear box provides a set of gear ratios to modify the speed-power (torque) profile to match the load requirement
  • 18. ELECTRIC AND HYBRID VEHICLES EV configurations An electric motor that has a constant power in a long range, a fixed gearing can replace the multispeed gearbox and reduce the need of a clutch Not only reduces the size and weight of the mechanical transmission, it also simplifies the drive train control because gear shifting is not required
  • 19. ELECTRIC AND HYBRID VEHICLES EV configurations M,FG and D can be further integrated into a single assembly while both axles point at both driving wheels The whole drive train is further simplified and compacted
  • 20. ELECTRIC AND HYBRID VEHICLES EV configurations D is replaced by using two traction motors Each of them drives one side wheel and operates at a different speed when the vehicle is running along a curved path
  • 21. ELECTRIC AND HYBRID VEHICLES EV configurations The drive train and M can be placed inside a wheel A thin planetary gear set may be employed to reduce the motor speed and enhance the motor torque
  • 22. ELECTRIC AND HYBRID VEHICLES EV configurations Mechanical gearing is avoided by connecting a low speed motor directly to the driving wheels The speed control of motor is the speed control of driving wheel But this arrangement requires a motor having a higher torque
  • 23. ELECTRIC AND HYBRID VEHICLES Performance of EVs Vehicle’s driving performance Acceleration time Maximum speed Gradeability Proper motor power rating and transmission parameters are the primary considerations to meet the performance specification The design of all these parameters depends on the speed-power (torque) characteristics of the traction motor
  • 24. ELECTRIC AND HYBRID VEHICLES Traction motor characteristics Variable speed motor characteristics
  • 25. ELECTRIC AND HYBRID VEHICLES Traction motor characteristics The characteristics is usually represented by a speed ratio x, defined as the ratio of its maximum speed to its base speed Low speed region (less than the base speed) motor has a constant torque High-speed region (Higher than the base speed) motor has a constant power
  • 26. ELECTRIC AND HYBRID VEHICLES Traction motor characteristics In low-speed operations, voltage supply to the motor increases with the increase of the speed through the electronic converter while the flux is kept constant After the base speed, the motor voltage is kept constant and the flux is weakened, dropping hyperbolically with increasing speed. Hence, its torque also drops hyperbolically with increasing speed At the point of base speed, the voltage of the motor reaches the source voltage
  • 27. ELECTRIC AND HYBRID VEHICLES Traction motor characteristics Speed- Torque characteristics different speed ratios x (x=2,4,6)
  • 28. ELECTRIC AND HYBRID VEHICLES Traction motor characteristics With a long constant power region, the maximum torque of the motor can be significantly increased, and hence vehicle acceleration and gradeability performance can be improved and the transmission can be simplified
  • 29. ELECTRIC AND HYBRID VEHICLES Vehicle performance Vehicle’s driving performance Acceleration time Maximum speed Gradeability
  • 30. ELECTRIC AND HYBRID VEHICLES Vehicle performance Acceleration time Acceleration performance of a vehicle is evaluated by the time used to accelerate the vehicle from a low speed to a higher speed (100km/h for passenger cars) For passenger cars, acceleration performance is more important than max. cruising speed and gradeability, since power rating of motor drive depends on acceleration performance
  • 31. ELECTRIC AND HYBRID VEHICLES Vehicle performance Maximum speed The maximum speed of a vehicle can be easily found by the intersection point of the tractive effort curve with the resistance curve
  • 32. ELECTRIC AND HYBRID VEHICLES Vehicle performance Gradeability It is defined as the highest grade a vehicle can ascend maintaining a particular speed The maximum grade that a fully laden vehicle combination is capable to maintain the forward motion on an uphill road at a certain constant speed at a certain friction level OR It is determined by the net tractive effort of the vehicle The gradeability at mid and high speeds is smaller than at low speed
  • 33. ELECTRIC AND HYBRID VEHICLES Tractive effort 𝒕 𝒎 𝒈 𝟎 𝒕 𝒅 𝒎 𝒅 𝒈 𝟎 The tractive effort developed by a traction motor on driven wheels And the vehicle speed Tm and are the motor torque output Nm speed in rpm ig is the gear ratio of transmission i0 is the gear ratio of final drive ηt is the efficiency of the whole driveline from the motor to the driven wheels and rd is the radius of the drive wheels
  • 34. ELECTRIC AND HYBRID VEHICLES The use of a multigear or single gear depends mostly on the motor speed-torque characteristics At a given rated motor power, if the motor has a long constant power region, a single gear transmission would be sufficient for a high tractive effort at low speeds, otherwise a multigear (more than two gears) transmission has to be used Transmission requirement
  • 35. ELECTRIC AND HYBRID VEHICLES Transmission requirement x=2, 3 gears, 3 speed regions
  • 36. ELECTRIC AND HYBRID VEHICLES Transmission requirement x=4, 2 gears, 2 speed regions
  • 37. ELECTRIC AND HYBRID VEHICLES Transmission requirement x=6, 1 gear, 1 speed regions
  • 38. ELECTRIC AND HYBRID VEHICLES Energy consumption Energy consumption
  • 39. ELECTRIC AND HYBRID VEHICLES The energy consumption is an integration of the power output at the battery The energy consumption is an integration of the power output at the battery terminals Energy consumption Energy consumption For propelling, the battery power output is equal to the resistance power and power losses in transmission and motor drive, including power losses in the electronics The efficiency of a traction motor varies its operating points on the speed- time curve (speed-power) plane, where the most efficient operating area exists
  • 40. ELECTRIC AND HYBRID VEHICLES The architecture of a hybrid vehicle is defined as the connection between the components that define the energy flow routes and control ports HYBRID VEHICLES
  • 41. ELECTRIC AND HYBRID VEHICLES Classification of Hybrid vehicles Classification of Hybrid vehicles HEVS Series hybrid Parallel hybrid Series–parallel hybrid Complex hybrid
  • 42. ELECTRIC AND HYBRID VEHICLES HYBRID VEHICLES HYBRID VEHICLES
  • 43. ELECTRIC AND HYBRID VEHICLES HYBRID VEHICLES HYBRID VEHICLES
  • 44. ELECTRIC AND HYBRID VEHICLES HYBRID VEHICLES HYBRID VEHICLES Configuration of a series hybrid electric drive train Configuration of a series hybrid electric drive train
  • 45. ELECTRIC AND HYBRID VEHICLES Operation modes Pure electric mode Pure engine mode Hybrid mode Engine traction and battery charging mode Regenerative braking mode Battery charging mode Hybrid battery charging mode Operation modes of a series hybrid electric drive train
  • 46. ELECTRIC AND HYBRID VEHICLES Pure electric mode Operation modes of a series hybrid electric drive train The engine is turned off and the vehicle is propelled only by the The engine is turned off and the vehicle is propelled only by the batteries Pure engine mode  The vehicle traction power only comes from the engine-generator, while the batteries neither supply nor draw any power from the drive train.  The electric machines serve as an electric transmission from the engine to the driven wheels
  • 47. ELECTRIC AND HYBRID VEHICLES Operation modes of a series hybrid electric drive train Hybrid mode The traction power is drawn from both the engine generator and the batteries Engine traction and battery charging mode The engine-generator supplies power to charge the batteries and to propel The engine-generator supplies power to charge the batteries and to propel the vehicle
  • 48. ELECTRIC AND HYBRID VEHICLES Operation modes of a series hybrid electric drive train Regenerative braking mode Battery charging mode  The engine-generator is turned off and the traction motor is operated as a generator  The power generated is used to charge the batteries The traction motor receives no power and the engine-generator charges the batteries
  • 49. ELECTRIC AND HYBRID VEHICLES Operation modes of a series hybrid electric drive train Hybrid battery charging mode Both the engine-generator and the traction motor operate as generators to charge the batteries Operation modes of a series hybrid electric drive train
  • 50. ELECTRIC AND HYBRID VEHICLES Series hybrid electric drive train Advantages Advantages Because electric motors have near-ideal torque–speed characteristics, they Because electric motors have near-ideal torque–speed characteristics, they do not need multigear transmissions. Therefore, their construction is greatly simplified and the cost is reduced Simple control strategies may be used as a result of the mechanical decoupling provided by the electrical transmission
  • 51. ELECTRIC AND HYBRID VEHICLES Series hybrid electric drive train Disadvantages Disadvantages in  The energy from the engine is converted twice (mechanical to electrical in the generator and electrical to mechanical in the traction motor)  The inefficiencies of the generator and traction motor add up and the losses may be significant The generator adds additional weight and cost The traction motor must be sized to meet maximum requirements since it is the only power plant propelling the vehicle
  • 52. Thank You Name : Latha N Department: School of Electrical and Electronics Engineering Contact : Email ID: latha.n@reva.edu.in Mobile No. : 9743994095
  • 53. Established as per the Section 2(f) of the UGC Act, 1956 Approved by AICTE, COA and BCI, New Delhi Electrical Power Utilization Course Code :B19EE4051 School of Electrical and Electronics Engineering, REVA University Latha N, Ass istant Professor A Y : 2 0 2 0 - 2 0 2 1
  • 54. COURSE CONTENTS UNIT – 2b: Electrolytic process Total duration = 12 Hours Fundamental principles Extraction, refining of metals and electroplating Factors affecting electro deposition process Power supply for electrolytic process Numerical
  • 55. ELECTROLYTIC PROCESS The process in which electrical energy is used to produce chemical changes . .
  • 58. ELECTROLYTIC PROCESS Manufacturing of chemicals Caustic soda Potassium permanganate Chlorine
  • 61. ELECTROLYTIC PROCESS Electrolysis  Electrolysis, process by which electric current is passed through a substance to effect a chemical change  The chemical change is one in which the substance loses or gains an electron (oxidation or reduction)
  • 63. ELECTROLYTIC PROCESS Faraday’s laws of Electrolysis The mass of the substance liberated during electrolysis is directly proportional to quantity of electricity flowing through the electrolyte First Law First Law Where, m = mass of the substance liberated in kg Z = a constant know as the electro-chemical equivalent of the substance in Kg/C I = current flowing in amperes t = time for which flows in seconds
  • 64. ELECTROLYTIC PROCESS Faraday’s laws of Electrolysis First Law First Law The electrochemical equivalent Z of a substance is defined as the amount of the substance deposited , when a current of 1A flows through the electrolyte for 1 second If, And Then, Unit is in kilogram per coulomb (kg/C)
  • 65. ELECTROLYTIC PROCESS Faraday’s laws of Electrolysis When same quantity of electricity is passed through several electrolytes, the mass of the substances liberated are proportional to their respective chemical equivalents or equivalent weights Second Law Second Law
  • 66. ELECTROLYTIC PROCESS Definitions Electrochemical equivalent (Z) ECE of a substance is the mass of it liberated in a process of electrolysis by the passage of unit quantity of electricity, i.e. by unit current (ampere) for unit time (second) The SI unit of ECE (Z), is the kg/Coulomb Atomic weight Atomic weight of an element is a number, which is the average of the masses of its various isotopes (protons=electrons, no. of neutrons different)
  • 67. ELECTROLYTIC PROCESS Definitions Formula weight Formula weight of a chemical entity (atom, radical, molecule, ion) is the sum of the atomic weights of its constituents Example: The formula weight of water (H2O) is two times the atomic weight of hydrogen plus one times the atomic weight of oxygen Numerically, this is (2×1.00797)+(1×15.9994) = 2.01594+15.9994=18.01534
  • 68. ELECTROLYTIC PROCESS Definitions Valency The Valency of an atom or radical (a group of atoms) is the no. of hydrogen atoms with which it will react chemically Valency is always an integer (i.e. 1,2,3..) but for a given atom or radical, it can have different values in different chemical reactions Example: Valency of Aluminium is 3
  • 69. ELECTROLYTIC PROCESS Definitions Equivalent weight It is defined as the mass of an element/compound/ion which combines or displaces 1 part of hydrogen or 8 parts of oxygen or 35.5 parts of chlorine by mass Example: Atomic weight of Silver is 107.88 and Valency is 1 Then , Equivalent weight is 107.88
  • 71. ELECTROLYTIC PROCESS Current efficiency Current efficiency is defined as “ The ratio of the actual quantity of substances liberated to the theoretical quantity” Definitions It is usually between 90 to 98%, for Chromium plating only about 12 to 15%
  • 72. ELECTROLYTIC PROCESS Energy efficiency Energy efficiency is defined as ratio of the theoretical energy required for depositing a certain quantity of the substance to the actual value of the energy required Definitions
  • 73. ELECTROLYTIC PROCESS Electrode Potential A potential difference exists between the anode and electrolyte and also between cathode and electrolyte, this potential difference is called electrode potential Depends on temperature and concentration of electrolyte
  • 74. ELECTROLYTIC PROCESS Calculation of current required From the ECE(kg/C) it is possible to calculate the theoretical value of current required to deposit any given quantity of metal or alternatively the amount of metal which should theoretically be deposited by a given current
  • 75. A sheet of iron having a total surface area of 0.36m2 is to be electroplated with copper to a thickness of 0.0254mm.Estimate the time required for the process? The iron will be made cathode and immersed, together with an anode of pure copper, in a solution of copper sulphate. Given density of copper as 8.96e+03kg/m3 , ECE of copper as Z=32.9e-08 kg/C, current density is 330A/m2 ELECTROLYTIC PROCESS Numerical - 1
  • 76.  Surface area = a = 0.36m2  Thickness = t = 0.0254mm  Density of copper = D = 8.96e+03kg/m3  ECE of copper = Z = 32.9e-08 kg/C  Current density = δ = 330A/m2 ELECTROLYTIC PROCESS Data Given: To find: Time required=T=? Numerical - 1
  • 77. ELECTROLYTIC PROCESS Solution - 1 Mass of the copper deposited = 9.144 x 10-6 m3 x 8.96e+03 kg/m3 Volume of the Iron Sheet = Surface Area of the Iron sheet x Thickness of sheet Volume of the Iron Sheet = 9.144 x 10-6 m3 Volume of the Iron Sheet = 0.36m2 x 0.0254mm Mass of the copper deposited = Volume of the Iron Sheet x Density Volume of the Iron Sheet = 0.36 x 0.0254 x 10-3 AH = 69.233 kg Mass of the copper deposited = 0.081930 kg = 0.082kg
  • 78. ELECTROLYTIC PROCESS Solution - 1 Current = I = 0.36m2 x 330A/m2 T = 0.585 Hrs Current = I = Surface Area x Current Density Current = I = 118.8 A
  • 79. Calculate the Ah required to deposit a coating of silver 0.1mm thick on a sphere of 10cm radius. Assume ECE of silver = 0.001118 g/C and density of silver to be 10.5 g/cm3. Assume that the energy efficiency is 95%. ELECTROLYTIC PROCESS Numerical - 2
  • 80.  Thickness = t = 0.1mm  Radius of sphere = r = 10cm  Density of silver = D = 10.5 g/cm3  ECE of silver = Z = 0.001118 g/C  energy efficiency = 95% ELECTROLYTIC PROCESS Data Given: To find: AH required = ? Numerical - 2
  • 81. ELECTROLYTIC PROCESS Solution - 2 Volume = Surface Area of Sphere x Thickness Volume = 12.5664 cm3 Mass of the silver deposited = Volume x Density Surface Area of Sphere = 4𝜋𝑟 Surface Area of Sphere = 1256.64𝑐𝑚 Surface Area of Sphere = 4𝜋 ∗ 10 Volume = 1256.64𝑐𝑚 x 0.1 x 10 Mass of the silver deposited = 12.5664 cm3 x 10.5 g/cm3 Mass of the silver deposited = 131.94 g
  • 82. ELECTROLYTIC PROCESS Solution - 2 AH = 32.78 g Theoretical Value of AH Actual AH = 34.50 g
  • 83. If 96500C of electricity liberate 1g equivalent of any substance, how long will it take for a current of 0.15A to deposit 20mg of Cu from a solution of copper sulphate? Chemical equivalent of Cu is to be taken as 32. ELECTROLYTIC PROCESS Numerical - 3
  • 84.  Current = I = 0.15A  Mass of copper deposited = 20mg  ECE of copper = Z = 32/96500 g/C ELECTROLYTIC PROCESS Data Given: To find: Time required = T = ? Numerical - 3
  • 85. ELECTROLYTIC PROCESS Solution - 3 AH = 0.01675 T = 402s T = 0.11168Hrs
  • 86. A rectangular plate 20 x 10cm is to be coated with Nickel with a layer of 0.2mm thickness. Determine the quantity of electricity in Ah and time taken for the process. Current density is 190A/m2 and current efficiency is 90%. Specific gravity (density) of nickel is 8.9g/m3. ECE of Nickel = 0.0010954kg/Ah ELECTROLYTIC PROCESS Numerical - 4
  • 87. A 20cm long portion of a circular shaft 10cm diameter is to be coated with a layer of 15mm Nickel. Determine the quantity of electricity in Ah and time taken for the process. Assume a current density of 195 A/m2 and current efficiency of 92%, Specific gravity (density) of Nickel is 8.9g/m3, ECE of Nickel = 1.0954kg/1000Ah ELECTROLYTIC PROCESS Numerical - 5
  • 88. The to The worn out part of a circular shaft 0.15m in diameter and 0.3m long is to be repaired by depositing on it 1.6mm of Nickel by electro-deposition process. Estimate the quantity of electricity required and the time taken, if the current density is 215A/m2. The energy efficiency of the process may be taken as 95%. The density of Nickel is 8.9e+03kg/m3 and ECE of Nickel is 30.349e-08kg/C ELECTROLYTIC PROCESS Numerical - 6
  • 89. Nickel coating of 1mm thickness is to be built on a cylindrical surface 15cm diameter and 20cm long in 1 ½ Hrs. Calculate the electrical energy needed if ECE of nickel is 0.3043 mg/C. Specific gravity (Density) =8.9g/m3 and voltage used in electroplating is 10V. ELECTROLYTIC PROCESS Numerical - 7
  • 90. Estimate the current required to produce 10g of caustic soda in 5min from a solution of sodium chloride given that ECE of sodium is 0.0002388g/C and atomic weights of sodium=23, Oxygen=16 and Hydrogen=1 ELECTROLYTIC PROCESS Numerical - 8
  • 91. A weighed copper plate is made as cathode in a copper sulphate voltammeter (electrolytic cell). At the end of two hours a weight of 50g was deposited on it. The current during the operation time was kept constant and the ammeter indicated 20A. Did the ammeter read correctly; if not what is the %age error?. Given atomic weight of copper=63.5; Hydrogen = 1; Silver = 108 and ECE of Silver=0.001118g/C, Valency of Copper=2, Valency of Silver=1 ELECTROLYTIC PROCESS Numerical - 9
  • 92. ELECTROLYTIC PROCESS Extraction of metals Extraction of metals Ore is treated with strong acid Ore is available in molten state
  • 93. ELECTROLYTIC PROCESS Extraction of metals Metal Treatment of ore Solution Consumption kwh/t (approx.) Aluminium - Fused cryolyte (combustible matter for firing mines) 20,000-25,000 Copper Roasted and leached (to moisten) with sulphuric acid Copper sulphate 2000-2500 Magnesium - Fused magnesium chloride or carnallite 17,000-20,000 Sodium - Fused sodium hydrate or sodium nitrate and sodium chloride 10,000-20,000 Zinc Leached with sulphuric acid Zinc chloride and zinc sulphate 3000-5000
  • 94. ELECTROLYTIC PROCESS Extraction of Zinc The ore, consisting largely of zinc oxide, treated with strong sulphuric acid, roasted and passed through various chemical processes to precipitate cadmium, copper and any other impurities; the resulting zinc sulphate solution is passed to the electrolytic cells The electrolytic cells consists of large lead-lined wooden boxes, each containing a no. of aluminum cathodes and lead anodes and carrying a current of several hundred and thousand Amperes, according to the size
  • 95. ELECTROLYTIC PROCESS Extraction of Zinc The current density on the cathodes is about 1100A/sq. m The potential drop in each cell is about 3.5V, so that 100 or 150 of them in series The zinc is deposited on the cathodes, which are removed once or twice a day for stripping (To peel) The energy consumed is of the order 3000 to 5000kWh per tonne
  • 96. ELECTROLYTIC PROCESS Extraction of Aluminium An example of the fused electrolyte process is the extraction of aluminium from its ores, bauxite and cryolite The bauxite is first treated chemically to reduce it to aluminium oxide and this is then dissolved in fused cryolite and electrolyzed The furnace in which the fusion and electrolysis take place consists of a shallow rectangular bath lined with carbon
  • 97. ELECTROLYTIC PROCESS Extraction of Aluminium Carbon anodes project downwards into the bath and the bottom of the bath forms the cathode The high temperature (1000 degree) necessary to keep the ores in a fused state is maintained by the Ohmic losses of the current passing through the electrodes and electrolyte
  • 98. ELECTROLYTIC PROCESS Extraction of Aluminium A furnace having an area of 13.6 sq.mt will require a pressure of 5 or 6V and a current of 40,000A Aluminium is deposited at the cathode and settles at the bottom of the bath, from which it is tapped off as required
  • 99. ELECTROLYTIC PROCESS Refining of metals Highly concentrated mixture of metals is subjected to electrolysis for recovering of metal in its purest form Recover precious metals like gold, silver, bismuth
  • 100. ELECTROLYTIC PROCESS Refining of metals Metal Solution Consumption kWh/tonne Copper Copper sulphate 150-300 Gold Chloride of gold 300-350 Iron Iron ammonium sulphate 1000-1500 Lead Lead fluosilicate 100-120 Nickel Nickel-chloride and sulphate 2500-4000 Silver Nitric acid and silver nitrate 400-420
  • 101. ELECTROLYTIC PROCESS Refining of Copper Copper is usually mined from its coal known as blister copper. It is about 98 to 99 per cent pure. Electro-refining process can easily make it 99.95% pure which makes it a good product A block of impure copper is taken as an anode or positive electrode Copper sulphate which is acidified with sulphuric acid is used as a graphite-coated electrolyte along with pure copper tubes, as a cathode or negative electrode
  • 102. ELECTROLYTIC PROCESS Refining of Copper In this phase of electrolysis copper sulfate divides into a positive ion of copper (Cu++) and a negative ion of sulphate (SO4—) The positive copper ion (Cu++) or cations travel towards the negative electrode made of pure copper where it absorbs the electrons from the cathode Cu atom is deposited on the cathode’s graphite layer
  • 103. ELECTROLYTIC PROCESS Electro deposition Electrolytic process in which one metal is coated over another metal or non metal in its pure form This process is used in electro-plating, electro-forming, electro-typing, electro- facing, electro-metallization , electro-deposition of rubber
  • 104. ELECTROLYTIC PROCESS Electro deposition Nature of electrolyte Current density Temperature Conductivity Electrolytic concentration Additional agents Throwing power Polarization Factors governing electro- deposition process
  • 105. ELECTROLYTIC PROCESS Electro deposition Nature of electrolyte  The electrolyte from which complex ions can be obtained, such as cyanides, provides a smooth deposit
  • 106. ELECTROLYTIC PROCESS Electro deposition Current density  The deposit of metal will be uniform and fine-grained if the current density is used at rate higher than that at which the nuclei are formed  The deposit will be strong and porous if the rate of formation of nuclei is very high due to very high current density
  • 107. ELECTROLYTIC PROCESS Electro deposition Temperature  A low temperature of the solution favours formation of small crystals of metal; and at high temperature, large crystals
  • 108. ELECTROLYTIC PROCESS Electro deposition Conductivity  The solution of good conductivity is important from the standpoint of view of economy in power consumption and also because it reduces the tendency to form trees and rough deposits
  • 109. ELECTROLYTIC PROCESS Electro deposition Electrolytic Concentration  Higher current density, which is necessary to obtain uniform and fine-grain deposit, can be achieved by increasing the concentration of the electrolyte
  • 110. ELECTROLYTIC PROCESS Electro deposition Additional Agents  The addition of acids or other substances to the electrolyte reduces its resistance  additional agents are glue, gums, dextrose, dextrin, gelatin, agar, alkaloids, albumen, phenol, glycerin, sugar, glucose, rubber influence nature of deposit  The crystal nuclei absorb the additional agent added in the electrolyte  This prevents it to have large growth and thus deposition will be fine-grained
  • 111. ELECTROLYTIC PROCESS Electro deposition Throwing power  It is the ability of electrolyte to produce uniform deposit on an article of irregular shape  Due to unequal distance, the resistance of the current path through the electrolyte for various portions of the cathode will be different  But the potential difference between the anode and any point on the cathode will be the same  And the result will be that the current density will be more on the portion nearer to anode and it will cause uneven deposit of the metal
  • 112. ELECTROLYTIC PROCESS Electro deposition Polarization  The rate of deposition of metal increases with the increase in electroplating current density up to a certain limit  after which electrolyte surrounding the base metal becomes so much depleted that the increase in current density does not cause increase rate of deposition  Increase in current density beyond this limit causes electrolysis of water and hydrogen liberation on the cathode  This hydrogen evolved on the cathode blankets the base metal which reduces the rate of metal deposition
  • 113. ELECTROLYTIC PROCESS Electro Plating Electroplating is electrolytic process in which superior or noble metal is deposited on an inferior or base metal Purpose of Electroplating To protect the metals against corrosion To give reflecting properties to the reflectors To give a shiny appearance to articles To repair the worn-out materials
  • 114. ELECTROLYTIC PROCESS Electro Plating  Electrolytic deposits are crystalline in nature and the crystals deposited must be very fine, coherent and uniform deposition  Proper current density value  Proper temperature level Example: For 1000 CC solution, 150-200gms of copper sulphate 25 – 35 gms of sulphuric acid Current density 150 – 400A/m2 Temperature 25 – 500C
  • 115. ELECTROLYTIC PROCESS Power supply for electrolytic process Power supply required for electrolytic process is low voltage DC supply For electro-deposition a power supply of 10 to 12 volts which can give 100 to 200 amperes is adequate Power Supply Using a Motor-Generator Set Using a metal Oxide Rectifier
  • 116. ELECTROLYTIC PROCESS Power supply for electrolytic process Using a Motor-Generator Set  The motor is an ordinary three phase induction motor and the generator is a heavy current, low voltage DC generator  The generator should preferably be separately excited  DC voltage can be controlled by controlling the excitation of the generator
  • 117. ELECTROLYTIC PROCESS Power supply for electrolytic process Using a metal Oxide Rectifier  Better efficiency at low voltages especially at low loads, occupies less space, has low maintenance cost  Recently the solid state rectifying devices employing germanium and silicon diodes have been developed for use
  • 118. Thank You Name : Latha N Department: School of Electrical and Electronics Engineering Contact : Email ID: latha.n@reva.edu.in Mobile No. : 9743994095