CELL HOUSE

CONSTRUCTION AND WORKING Cathodes Anodes Electrolyte Voltage supply cooling towers The cell house consists of a set of 32 cells each comprising of 84 cathodes and 85 anodes. The nominal capacity of the house is 30,000 TPY. The electrodes facing outwards are cathodes and those facing inwards are the anodes. Cathodes are made of aluminium and anodes are a combination of 99.25% lead and 0.75% arsenic. The electrolyte used is ZnSO4. Electrolyte comes from the ECGC of neutral leach. Each cell will have a voltage of 3.2V, and ampere rating of 125KA. Zinc gets deposited on the cathode and is taken out every 48 hours. A whole cell is taken at a time. The zinc deposited on the cathode is stripped off by means of horizontal and vertical shear. Those strips, which cannot be stripped mechanically, are stripped manually. These zinc strips obtained are stacked and then sent to the melting section. The electrodes, which are malleable in nature, are straightened by means of a clapping mechanism. The electrodes are then washed with high-pressure water. Passing through cooling towers, where a fan is rotated at high speed, cools the electrolyte. Waste gases escapes through the demisters. When the electrolyte passes from one end to the other, only 5% of zinc gets absorbed on the cathode. Cell cleaning MnSO4 + O2

MnO2

(anode)

The MnO2 on the anode surface and cell bottom are periodically removed from the cells. Tools for cell cleaning are made of plastic or wood to avoid damaging of paraliners IMPURITIES IN THE ELECTROLYTE Elements having a lower electrochemical potential than the potential of zinc such as Pb, Cd, Cu, Fe, Ag set down at the cathode before zinc and the cathode quality will depend more or less on the perfect elimination of these impurities. Impurities lowering the overvoltage such as Ge, Ni, Cu, Fe, CO, As, Sb improve the hydrogen production and causes insufficient adherence of zinc to the cathode. PROCESS CONTROL Basic reactions ZnSO4 Zn++ + SO4--+ SO4 + 2H H2SO4 Reacting ions Zn2+ + 2e- Zn 2H2O 4H+ + 4e- + O2 General formula ZnSO4 + H2O H2SO4 + Zn + O2 Oxygen liberated at the anode will oxidize Mn2+ ions from the electrolyte to Mn4+. MnSO4 + O2 MnO2 + H2SO4

PROCESS PARAMETERS Inorder to obtain a zinc sheet on the aluminium cathode, thick enough for mechanical stripping, at least 14KA/m2 have to be consumed. The maximum acceptable zinc sheet thickness on the aluminium cathode for mechanical stripping is reached after a current consumption of 22KA/m2. The minimum current density during the stripping process is 180A.h/m2. The current density during can be lowered below 160 A.h/m2 down to 60 A.h/m2 only if the cathodes in the cells are covered with a solid zinc layer.

REAGENTS AND THEIR USE

STRONTIUM CARBONATE

Purpose Consumption

Characteristics Composition

To reduce the lead content in the cathode zinc 4.5 kg strontium carbonate per ton of cathode zinc produced. Or 45 l of 100 g/l suspension per ton of cathode zinc produced. Fine ground powder Sr : 53 %, Ba : 2% Ca : 0.2 % As,Cu,Ni,Co,F,Cl,Ge,Fe : Traces To reduce the negative effect of impurities like cobalt, nickel etc. It increases the adherence of the zinc sheets to the aluminium cathode It makes the deposited zinc brittle. 12 gram of gelatine per cubic meter of purified solution fed into launder. Or 0.95 l of 12.7 gram per liter gelatine solution per cubic meter solution fed into the launder Fine white powder To reduce acid mist above the cells by foam formation 4 gram MPC per cubic meter of purified solution fed into launder. Or 0.4 liter of 10 gram per liter MPC solution per cubic meter of purified solution fed into the launder. Inhibits the growth of dendrites on the cathode zinc surface. Stabilizes the foam generated by the MPC. 1kg of sodium silicate per ton of cathode zinc produced. Or 33 liters of 30 gram per liter solution per ton of cathode zinc produced.

GELATINE

Purpose

Consumption

Characteristics
LIQUORS

Purpose Consumption

SODIUM SILICATE

Purpose

Consumption