Electrorecovery Processes

1 The average energy requirement for a copper electrowinning cell is 2.0kWh/kg Cu

whereas a copper electrorefining cell may consume only 0.25kWh/kg Cu. With
reference to major factors which influence power consumption in electrolytic
processes, briefly indicate the reasons for the difference.

2 A copper electrowinning cell operates with 90% current efficiency to produce 60g of
copper metal in 1 hour. The cathode area is 1m2. What is the current density at the
cathode? Molecular mass of copper is 63.55g

3 A zinc electrowinning plant is operating at a current density of 700A/m2. The anodic

and cathodic overpotentials are 0.5V and 0.1V respectively and the voltage drop due
to poor connection at contacts is 0.2V. If the distance between the electrodes is 10cm
and the solution conductivity k is 100 ohm-1m-1 . Calculate the power consumption in
KWH/kg assuming a cathode area of 1m2 and a cathode current efficiency of 90%.

EZn 2 / Zn  0.76V EO2 / H 2O  1.23V

4 One of the major issues facing the metals industry is the energy required for production.
A series circuit has been arranged to compare the energy requirements for electrowinning and
electrorefining of copper. The circuit has one cell corresponding to the electrowinning of copper
(insoluble anode) while the other is similar to that encountered in electrorefining (soluble copper
anode). The current is set at 210 mA and this gives a current density of approximately
35mA/cm2.

Data given

Electrolyte -50gpl Cu2+ as CuSO4, 150gpl H2 SO4 remainder distilled water.

Cathode: copper sheets
Anode: copper sheets (electrorefining) lead sheet: electrowinning
Equipment: DC power supply, ammeter, voltmeter

The measured potential were

Refining cell: 0.3V

Electrowinning cell: 1.7volts

a) Indicate the net reactions occurring for these two processes

b) Calculate the time required to produce a tonne of copper.
 c) Calculate the energy required per tonne of copper produced by electrowinning and
electrorefining assuming 100% current efficiency.
d) Compare your calculated values of energy per ton of Cu with those obtained in
commercial operations. Discuss the differences if any that occur.

5 A circular plate 300mm in diameter is used to electrowin nickel from a sulphate solution.
The thickness of the resulting cathode is 2.5mm. If the cathode current density is 300Am-2 and
the cathode efficiency is 94% calculate the electrowinning time. Assume plating happens on
both side of the electrode and density of nickel is 8900kgm-3