CA1312219C - Process of controlling foam which limits acids mist during electrowinning - Google Patents

Process of controlling foam which limits acids mist during electrowinning

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Publication number
CA1312219C
CA1312219C CA000591607A CA591607A CA1312219C CA 1312219 C CA1312219 C CA 1312219C CA 000591607 A CA000591607 A CA 000591607A CA 591607 A CA591607 A CA 591607A CA 1312219 C CA1312219 C CA 1312219C
Authority
CA
Canada
Prior art keywords
electrolyte
foam
surfactant
test chamber
height
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CA000591607A
Other languages
French (fr)
Inventor
Tei Stewart Sanmiya
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Vale Canada Ltd
Original Assignee
Vale Canada Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vale Canada Ltd filed Critical Vale Canada Ltd
Priority to CA000591607A priority Critical patent/CA1312219C/en
Application granted granted Critical
Publication of CA1312219C publication Critical patent/CA1312219C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N13/00Investigating surface or boundary effects, e.g. wetting power; Investigating diffusion effects; Analysing materials by determining surface, boundary, or diffusion effects
    • G01N13/02Investigating surface tension of liquids
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25CPROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
    • C25C7/00Constructional parts, or assemblies thereof, of cells; Servicing or operating of cells
    • C25C7/06Operating or servicing
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N13/00Investigating surface or boundary effects, e.g. wetting power; Investigating diffusion effects; Analysing materials by determining surface, boundary, or diffusion effects
    • G01N13/02Investigating surface tension of liquids
    • G01N2013/0241Investigating surface tension of liquids bubble, pendant drop, sessile drop methods
    • G01N2013/025Measuring foam stability
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N13/00Investigating surface or boundary effects, e.g. wetting power; Investigating diffusion effects; Analysing materials by determining surface, boundary, or diffusion effects
    • G01N13/02Investigating surface tension of liquids
    • G01N2013/0275Investigating surface tension of liquids involving surface-active agents

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  • Chemical & Material Sciences (AREA)
  • Immunology (AREA)
  • General Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Pathology (AREA)
  • General Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Biochemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electrolytic Production Of Metals (AREA)

Abstract

A PROCESS OF CONTROLLING FOAM WHICH
LIMITS ACID MIST DURING ELECTROWINNING

ABSTRACT

The process for measuring foaming capacity of surfactant used in controlling acid mist production during electrowinning. The invention sends a portion of an electrolyte containing surfactant to a test chamber. The electrolyte is gasified in the test chamber to form bubbles which rise and accumulate above the electrolyte in the test chamber. The foam layer has a height proportional to the foaming capacity of the electrolyte. The height of the foam in the test chamber is measured to determine the amount of surfactant to add to the electrolyte for effective foaming in the electrolytic cell.

Description

~ 3~L22~

A PROCESS OF CONTROLLING FOAM WHICH
LIMITS ACID ~IST DURING ELECTROWINNING

The present invention relates to foam used in limiting acid mist during electrowinning. More particularly, it relates to controlling the level of surfactant used in producing foam bubbles.

BACKGROUND OF THE ART AND PROBLEM

During the copper electrowinning process from sulfate electrolyte, oxygen bubbles are generated at the anodes. These bubbles have the capability of bursting at the electrolyte air interface ~surface) and producing acid mist in the electrowinning tankhouse. A surfactant is added to the electrolyte to effect the bubbles to form a stabilized protective foam layer on the electrolyte surface. This foam layer prevents bubbles from bursting acld directly into the atmosphere. If the protective layer of foam becomes too thick, the foam deposits on bus bars which supply energy to the anodes and to the cathodes. The foam evaporates on the bus bars leaving a deposit which interferes with the conductivity at : .

~3 ~ 22~
the bus bar connections to the anodes and cathodes.
There are several factors which affect the height of the foam ]ayer. The major factors are: addition rate of fresh surfactant5 addition rate of recycled surfactant, plating rate, electrolyte flow rate through the cell, anode surface condition and temperature. The increase of fresh and recycled surfactant increases the amount of ~oam produced. The amount of foam produced is also increased by increasing the metal deposition rate, which increases the rate of 2 production. Increasing the flow rate through the cell, increases the surfactant in the cell, which increases the foam produced. A rough clean anode surface produces an increased number of small bubbles having a greater surface area than a decreased number of large bubbles. The resulting small bubbles remain intact longer, increasing the level of the foam. An increase in temperature has also been found to increase the life and thickness of the foam.
During commercial electrowinning the above factors may constantly change. For this reason the rate or amount of fresh surfactant added to the electrolyte must often be ad~usted. This ad~ustment is difficult to perform by visual inspection of the electrolytic cells, because it may take several hours for the increased or decreased amount of surfactant to reach a steady state when electrowinning on a large scale.
An improved method of controlling foam levels during electrowinning is desired to eliminate open foam-free electrolyte surface which allows acid mist to flow directly into the atmosphere and over production of foam which adversely affects the bus bar contacts.

SUM~IARY OF THE INVENTION

The present invention contemplates a process for measuring foaming capacity of surfactant to effect foaming used in controlling acid mist production during electrowinning. An electrolyte containing surfactant is provided for use in an electrolytic cell. A
portion of the electrolyte containing surfactant is sent ~o a test chamber. The electrolyte in the test chamber is gasified to produce ~3~2:~
bubbles which rise and accumulate above the electrolyte in the test chamber as a foam layer. The foam layer has a height proportional to the foamlng capacity of the electrolyte. The height of the foam in the test chamber is measured to determine the amount of surfactant to add to the electrolyte for effective foaming in the electrolytic cell.
Preferably, a probe in the chamber produces a signal which indicates the height of the foam. The signal controls an automatic adjustable pump which controls addition of the surfactant to the electrolyte. The pump preferably increases the flow of surfactant when the signal indicates a drop in foam below a predetermined level.
The pump decreases the flow of surfactant when the signal indicates a raise in foam level above the predetermined level.

BRIEF DESCRIPTION OF THE DRAWING

Figure 1 is a schematic view of a test chamber which controls the flow of surfactant into a constant head tank for supplying a stream of electrolyte for electrowirming in an electrolytic cell.

PARTICULAR DESCRIPTION OF THE INVENTION

Referring to Figure 1, constant head tank 10 supplies a stream of electrolyte such as, aqueous sulfuric acid electrolyte 12 containing surfactant through a gravity feed pipe 14 to an electrolytic cell 15 for electrowinning. Bypass inlet pipe 16 transports electrolyte at an essentia]ly constant rate into a rectang~larly shaped test chamber 20. Electrolyte 12 flows from test chamber 20 out overflow outlet 17. A skimmer 18 extends across the test chamber 20 to prevent foam 30 from exiting through outlet 17.
The overflow outlet 17 may transport electrolyte 12 to electrolyte cell 15 or back to the constant had tank lO. Baffles 19 and 21 extend across the test chamber 20 to bufer the velocity of electrolyte 12 from inlet pipe 16. The flow of electrolyte 12 -4- ~3~22~9 P~-31~9 through the test chamber 20 ia buffered to prevent movement of the foam layer 30 from currents of electrolyte 12 which would di~rupt the level of -the foam, decrea~ing the accuracy of the test chamber 20.
Test chamber 20 can be maintained at the temperature of electrolytic cell 15 by thermostat maans not illustrated.
A pump sends a ~as such a3 air, nitrogen or oxygen at an e~sentially constant rate through a flowmeter. The flowmeter iq used to determine whether or not the air i~ flowing at a constant rate. The air flows at a con3tant rate throu~h a heat exchanger 25.
The heat exchanger 25 provides a 3upply of air to porous glass 26 at a temperature nea~ the temperature of the electrolyte 12. Heat exchanger 25 is preferably constructed out of stainles~ steel or of other corrosive re~istant materials having good thermal conductivity properties. After the air is pumped through heat exchanger 25, the air is forced through porou~ glas~ 26 to create air bubbles 28.
The air bubbles 28 rise to the surface to form a foam layer 30. The height of the foam layer 30 reache~ a steady state when the rate of ga~ entering the foam layer equals the rate of gas entering the atmo phere. The level of the foam 30 i~ an effective measure of the foaming capacity of the electrolyte 12. Changes in the foaming capacity of the electrolyte predict increases and decrease3 in the height of the foam 31 in the electrolytic cell 15.
A decrease of the foam height in the test chamber 20 indicates a future decrease in the foam height in the electrolytic cell 15.
Similarly, an increase of foam height in the test chamber 20 indicates a future increase of foam 31 in the electrolytic cell 15.
The rate oP adding surfactant is adjusted according to the predictions of the test chamber 20 to avoid substantial decreases and increase~ in the layer of foam 31.
~ surfactant 3uch as alkyl diphenyl oxide disulfonate is supplied from a drum through pipe 34, adju~table valve 36, and a rotometer to a tee connection 40. Water is supplied from pipe 42 through valve 44, through a second rotometer to tee connection 40.
If the surfactant i~ alkyl diphenyl oxide di3ulfonate, the surfactant is corrosive and should be mixed with about 10 part~ water per one part surfactant to reduce corrosion. The rotometers and are used to monitor the 10 to 1 ratio and the valve~ 36 and 44 are used to adjust the flow rates of the surfactant and the water to achieve the desired , ~,,, . "

~ 3 ~
-5- PC~3~

10 to 1 ratio. The water and ~urfactant ~olution travel3 through pipe 48 to an adjuatable pump. The adjustable pump, ~uch as worm gear type pump, ~upplies surfactant and water at a con~i~tent controllable rate through pipe 52 to the electrolyte constant head tank 10. The flow rate of the ~urfactant into the con~tant head tank, is adjusted with a rheostat which controls the revolution rate of the pump. In the con~tant head tank 10, the surfactant is dissolved into the electrolyte. The recycle pipe 54 al~o ~upplies recycled ~urfactant to the constant head tank 10. This recycled surfactant i9 supplied from the cell outlet pipe 56 and from the washing of cathodes 58. Skimmer S9 prevents foam 31 from flowing directly out cell outlet pipe 56. At the anode~ 60, oxygen bubble~
61 are produced. Oxygen bubbles 61 and the stabilizing surfactant form the foam layer 31.
Preferably a foam levsl probe send~ a ~ignal indicating the height of the foam to a controller. The probe may consist of a capacitance type probe or any other probe ~uitable for measuring the foam height. The controller is linked to and electrically controls the adjustable pump. The controller increases adju table pump when the level of the foam 30 ha~ fallen below a predetermined value. The predetermined value i9 a specific Ievel of foam in the test chamber which corre~ponds to an acceptable level of foam in the electrolytic cell. Similarly, the controller decrea~es adjustable pump when the level of foam 30 ha~ risen above the predetermined value.
Alternatively, the controller may be constructed to operate an adjustable valve on pipe 52 to increase and decrease surfactant flow.
A less de3irable alternative would be to ~imply place a foam level probe into an électrolytic cell and connect the probe to a controller. This alternative would operate~ but it would not have the effectiveness and accuracy of the invention, due to the extended lag time required for the foam level to reach a 3teady state.
Typical lag times required for the foam level to reach steady state are often between 3 and 4 hours. The invention by comparison measures almost immediate changes in foaming potential in the electrolyte, providing an effective and accurate proce~3 for controlling foam level in an electrolytic cell.
The proce~ of this invention ha~ proven to be an effective means of controlling foam height in electrolytic cells. The amount , . , 13~2~L9 of surfactant added is ad~usted to the several factors which affect foam height with sufficient speed as to prevent the uncovered electrolyte problems w~ich results from insufficient surfactant and to limit the conductivity problems occurring with the bus bars in the S electrolytic cells associated with over supply of surfactant.
While in accordance with the provisions o~ the statute, there is illustrated and described herein specific embodiments of the invention, those skilled in the art will understand that changes may be made in form of the invention covered by the claims and the certain features of the invention may sometimes be used to advantage without a corresponding use of the o~her features.

Claims (7)

1. A process for measuring foaming capacity of surfactant used in controlling acid mist production during electrowinning, a) providing an electrolyte containing surfactant to effect foaming in an electrolytic cell, b) sending a portion of the electrolyte containing surfactant to a test chamber, c) gasifying the electrolyte in the test chamber to form bubbles which rise and accumulate above the electrolyte in the test chamber as a foam layer having a height proportional to the foaming capacity of the electrolyte, and d) measuring the height of the foam in the test chamber to determine the amount of surfactant to add to the electrolyte for effective foaming in the electrolytic cell.
2. The process of Claim 1 wherein a probe in the chamber produces a signal which indicates the height of the foam.
3. The process of Claim 2 wherein the signal controls an automatic adjustable pump which controls addition of the surfactant to the electrolyte, the pump increasing the flow of surfactant when the signal indicates a drop in foam level below a predetermined level and decreasing the flow of surfactant when the signal indicates a rise in foam level above a predetermined level.
4. The process of Claim 1 wherein the bubbles formed are air bubbles.
5. The process of Claim 1 wherein a portion of the electrolyte is continuously sent to the test chamber.
6. The process of Claim 1 wherein the stream of electrolyte is an aqueous sulfuric acid electrolyte.
7. The process of Claim 6 wherein the surfactant is an alkyl diphenyl oxide disulfonate.
CA000591607A 1989-02-21 1989-02-21 Process of controlling foam which limits acids mist during electrowinning Expired - Lifetime CA1312219C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA000591607A CA1312219C (en) 1989-02-21 1989-02-21 Process of controlling foam which limits acids mist during electrowinning

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA000591607A CA1312219C (en) 1989-02-21 1989-02-21 Process of controlling foam which limits acids mist during electrowinning

Publications (1)

Publication Number Publication Date
CA1312219C true CA1312219C (en) 1993-01-05

Family

ID=4139659

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000591607A Expired - Lifetime CA1312219C (en) 1989-02-21 1989-02-21 Process of controlling foam which limits acids mist during electrowinning

Country Status (1)

Country Link
CA (1) CA1312219C (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014001964A3 (en) * 2012-06-27 2014-04-17 Koninklijke Philips N.V. An apparatus and a method of generating bubbles and foams
CN104520242A (en) * 2012-06-27 2015-04-15 皇家飞利浦有限公司 An apparatus and a method of generating bubbles and foams

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014001964A3 (en) * 2012-06-27 2014-04-17 Koninklijke Philips N.V. An apparatus and a method of generating bubbles and foams
CN104520242A (en) * 2012-06-27 2015-04-15 皇家飞利浦有限公司 An apparatus and a method of generating bubbles and foams
JP2015528855A (en) * 2012-06-27 2015-10-01 コーニンクレッカ フィリップス エヌ ヴェ Apparatus and method for generating bubbles and bubbles
CN104520242B (en) * 2012-06-27 2016-11-02 皇家飞利浦有限公司 Generate bubble and the apparatus and method of foam
RU2640242C2 (en) * 2012-06-27 2017-12-27 Конинклейке Филипс Н.В. Device and method for bubbles and foams generation
US9885120B2 (en) 2012-06-27 2018-02-06 Koninklijke Philips N.V. Apparatus and a method of generating bubbles and foams

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