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    Dr. SB Arya, NITK Surathkal, Mangalore 1

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    Athlur Sai Kiran
    Electrometallurgy involves the conversion of metallic salts, oxides, or sulfides into metals through electrolysis. There are two main processes: electrowinning to extract metals like copper, zinc, and nickel from their salts; and electrorefining to purify impure metals like copper. Electrolysis can be done in aqueous solutions or fused salts, depending on the standard electrode potential of the metal. Electrorefining is used to produce very pure metals by dissolving the impure metal anode and selectively plating only the metal onto the cathode.

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    Dr. SB Arya, NITK Surathkal, Mangalore 1

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    Athlur Sai Kiran
    20 views18 pages
    Electrometallurgy involves the conversion of metallic salts, oxides, or sulfides into metals through electrolysis. There are two main processes: electrowinning to extract metals like copper, zinc, and nickel from their salts; and electrorefining to purify impure metals like copper. Electrolysis can be done in aqueous solutions or fused salts, depending on the standard electrode potential of the metal. Electrorefining is used to produce very pure metals by dissolving the impure metal anode and selectively plating only the metal onto the cathode.

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    Electrometallurgy involves the conversion of metallic salts, oxides, or sulfides into metals through electrolysis. There are two main processes: electrowinning to extract metals like copper, zinc, and nickel from their salts; and electrorefining to purify impure metals like copper. Electrolysis can be done in aqueous solutions or fused salts, depending on the standard electrode potential of the metal. Electrorefining is used to produce very pure metals by dissolving the impure metal anode and selectively plating only the metal onto the cathode.

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    © All Rights Reserved
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    Download as pdf or txt
    20 views18 pages

    Dr. SB Arya, NITK Surathkal, Mangalore 1

    Uploaded by

    Athlur Sai Kiran
    Electrometallurgy involves the conversion of metallic salts, oxides, or sulfides into metals through electrolysis. There are two main processes: electrowinning to extract metals like copper, zinc, and nickel from their salts; and electrorefining to purify impure metals like copper. Electrolysis can be done in aqueous solutions or fused salts, depending on the standard electrode potential of the metal. Electrorefining is used to produce very pure metals by dissolving the impure metal anode and selectively plating only the metal onto the cathode.

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    of 18

    Dr.

    SB Arya, NITK Surathkal, Mangalore 1


    Electrometallurgy

    Electrometallurgy deals with the


    conversion of metallic salts, oxides or sulfides into
    metals (electro-winning)
    Purification of the metals (electro-refining)

    Dr. SB Arya, NITK Surathkal, Mangalore 2


    Main electrolysis processes:
     Aqueous salt electrolysis: electrowinning of
    metals (Cu, Zn, Ni, Co, Cd and Cr) from their salts
    and electrorefining of impure metals (copper, nickel,
    lead and tin)
    Fused salt electrolysis: electrowinning of
    Magnesium from MgCl2, and
    Aluminum from alumina

    The extraction of metals by electrolysis of salts (chlorides or sulfates) in


    an aqueous solution is limited by the discharge of H+ ions.

    Standard electrode potentials of Al -1.66 V, Ti -1.75 V, Mg -2.03 and Na -


    2.71 V(SHE) prevent their electrolysis in an aqueous medium.

    Dr. SB Arya, NITK Surathkal, Mangalore 3


    Electrolysis
    • is basically the decomposition of a liquid (aqueous solution of a salt or mixture of fused salts or ionic
    compounds) by the passage of an electric current.
    • Electrolytic process is essentially based on chemical reactions involving ions (anions and/or cations) and
    electrons which may be represented by electrochemical equations.

    Anodic Reactions
    Al → Al3+ + 3e
    Fe → Fe2+ + 2e
    Cathodic Reactions
    2H+ + 2e → H2↑

    Cell Potential
    The minimum theoretical cell voltage, Ecell required for electrolysis significantly varies for
    aqueous and fused electrolytes
    (ΔG = -nFE cell
    4
    Zn | Zn (a1 )┊
    2+
    ┊Cu (a2 ) | Cu 2+
    Dr. SB Arya, NITK Surathkal, Mangalore 5
    Electroplating

    Dr. SB Arya, NITK Surathkal, Mangalore 6


    Dr. SB Arya, NITK Surathkal, Mangalore 7
    E-pH relationship or Pourbaix diagram

    Dr. SB Arya, NITK Surathkal, Mangalore 8


    Electro-refining
     In an electro-refining process, the anode is the impure metal and the
    impurities must be lost during the passage of the metal from the
    anode to the cathode during electrolysis, i.e
     The electrode reactions are, at the anode:
    M → Mn+ + ne
     At the cathode:
    Mn+ + ne → M
     Electro-refining of metals :1000-100,000 ton/year.
     Larger operation to separate and recover pure metals from both scrap
    and primary ores.
     Electrorefining often provides a particularly high purity of metal. All
    the other components of the anode remain in solution or form slimes
    in the electrolytic bath
     Examples: electrorefining of copper, nickel, lead and tin;
    Dr. SB Arya, NITK Surathkal, Mangalore
     electrorefining of nickel mattes

    9
    Characteristic of this electrolysis:

    Low Ohmic drop(IR)


    High current efficiency is high (about 95%) and
    Energy consumption is low
    The operating conditions ensure this selective deposition.

    Dr. SB Arya, NITK Surathkal, Mangalore 10


    Refining of copper
    o Fire-refined copper can not be use for many applications
    due to presence of oxygen , sulphur and other impurities
    o The copper anodes from fire refining are placed in a tank
    filled with solution of copper sulphate to which is added
    some sulphuric acid as electrolyte.
    o The cathodes are pure copper starting sheets suspended
    between the anodes.
    o On passing of the current through the electrolyte, the anode
    is dissolved, anode copper passes into solution and the
    copper ions discharge at the cathodes forming deposits of the
    pure metal.

    Dr. SB Arya, NITK Surathkal, Mangalore 11


    The electro-refining of Cu
    (purposes)
     Elimination of unwanted impurities; cathode copper
    typically has a purity > 99.9% wt Cu, with < 0.005 % total
    metallic impurities
     Separation of valuable impurities which can be recovered
    in other processes.
     Ag, Au and Pt are more noble than copper and therefore
    will not dissolve anodically. They will be found as metals in
    the anode slime;
     Sn, Bi and Sb dissolve anodically but will precipitate in the
    electrolyte as oxide or hydroxide compounds which will be
    found in the anode slime. Dr. SB Arya, NITK Surathkal, Mangalore

    12
    Electrolytic Cell for copper Refining

    Dr. SB Arya, NITK Surathkal, Mangalore 13


    Anodes and cathodes:
     Anodes are usually 40-50 mm thick and 250-320 kg in
    weight.
     Starting sheets are usually made by depositing copper on
    rolled and stretched copper blanks in an electrolytic bath.
     The blanks are first coated with a mixture of graphite and oil,
    to allow the sheets of copper deposits to be readily stripped
    from the blank.
     Starting sheets are 30-50 mm wider and longer than the
    anodes .
    Typical tank sizes: 3-5 m (l)×1 - 1.1 m (w) × 1 - 1.3 m
    deep (but depend on of plate used)

    Dr. SB Arya, NITK Surathkal, Mangalore 14


    Electrowinning

    Dr. SB Arya, NITK Surathkal, Mangalore 15


    Electrowinning Aluminum

    Dr. SB Arya, NITK Surathkal, Mangalore 16


    Overall reaction

    Dr. SB Arya, NITK Surathkal, Mangalore 17


    Electrowinning Aluminum

    Purified Al2O3 in molten cryolite (Na3AlF6, melting


    point 1012C).

    Anode: C(s) + 2O2-(l)  CO2(g) + 4e-


    Cathode: 3e- + Al3+(l)  Al(l)

    The graphite rods are consumed in the reaction.

    Dr. SB Arya, NITK Surathkal, Mangalore 18

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