With the rapid development of electronics, electric power,
new energy and other industries, copper electrolytic as the
core raw material of high-purity metal materials, market
demand continues to rise. The precision and environmental
protection of its manufacturing process directly affects the
quality of copper and the performance of end products.
This article will deeply analyze the manufacturing process
of copper electrolysis, technical points and industry trends,
to provide practical reference for practitioners.
First, copper cathode manufacturing process:
why become industrial “gold”?
Electrolytic copper (purity ≥ 99.95%) is widely used because of its
excellent conductivity, ductility and corrosion resistance:
Power transmission: cable, transformer, circuit board core
conductor materials;
New energy field: lithium battery anode materials, photovoltaic
module connectors;
High-end manufacturing: semiconductor chip lead frame,
precision instrument components.
The stability of high-purity copper, making it an irreplaceable
“basic material” for modern industry.
Second, electrolytic copper manufacturing
process details
1. Preparation of raw materials: crude copper and electrolytic solution
Source of crude copper: extracted from copper concentrate by pyrometallurgy
(such as flash smelting, converter blowing), the purity of about 98% -99%;
Electrolyte preparation: copper sulfate (CuSO₄) solution as the main, adding
sulfuric acid (H₂SO₄) to enhance the conductivity, the temperature is controlled at 50-60 ℃.
2. Electrolytic refining: core process steps
Electrolytic tank structure: anode (crude copper plate) and cathode (pure
copper sheet/titanium plate) are arranged alternately, immersed in electrolyte;
Energization reaction: Under the action of direct current, the crude copper
at the anode is dissolved (Cu → Cu²⁺ + 2e-), and copper ions migrate to
the cathode for precipitation (Cu²⁺ + 2e- → Cu);
Impurity treatment: precious metals (gold, silver) are deposited as anode
mud, which can be recycled; other impurities (iron, zinc) are dissolved in
the electrolyte, which is periodically purified.
3. Post-treatment: Finished product processing and quality control
Stripping of copper cathode: After the electrolysis cycle (usually 7-15 days),
strip the pure copper from the cathode plate;
Cleaning and drying: remove residual electrolyte on the surface to
avoid oxidation;
Testing and grading: ensure copper purity ≥99.95% through spectral
analysis and conductivity test, and grade and pack according to
international standards (e.g. ASTM B115).
III. Technical difficulties and innovation
direction
1. Process optimization key points
Current efficiency improvement: control current density (200-300 A/m²),
electrolyte circulation speed, reduce energy consumption;
Impurity control: real-time monitoring of the concentration of iron,
arsenic and other impurities in the electrolyte to avoid cathode copper
surface tumor;
Energy-saving design: adopting reverse pulse power supply and waste
heat recovery system to reduce production cost.
2. Green Manufacturing Trends
Wastewater recycling: membrane filtration technology recovers copper
sulfate, realizing “zero wastewater discharge”;
High-efficiency purification of anode sludge: biometallurgy, high-pressure
oxidation method to extract precious metals, resource utilization rate
of over 99%;
Low-carbon electrolysis: introduction of green power (wind power,
photovoltaic) power supply, reducing carbon footprint.
Fourth, industry applications and future
prospects
5G and semiconductor: surge in demand for ultra-high purity copper
(6N grade), promoting electrolysis process to nanoscale purification;
New energy vehicles: copper usage accounts for 4 times that of
traditional vehicles, driving the expansion of copper electrolysis capacity;
Intelligent upgrade: AI algorithm regulates electrolysis parameters
in real time, realizing “unmanned” production.
V. Frequently Asked Questions (FAQ)
Q1: What is the difference between electrolytic copper
and ordinary copper?
Electrolytic copper has higher purity (≥99.95%), significantly better
conductivity and ductility than pyrolytic copper (purity
of about 99%), suitable for precision industrial scenarios.
Q2: How to avoid pollution during electrolysis?
Acid mist and heavy metal emissions can be effectively controlled
through closed electrolyzer design, electrolyte online purification
system and exhaust gas absorption device.
Q3: How to reduce the cost of copper electrolysis production?
Optimizing current efficiency, recycling precious metal by-products,
and using renewable energy for power supply are key cost reduction paths.
Conclusion
The copper cathode manufacturing process combines the essence of
metallurgy, chemistry and engineering technology, and its continuous
innovation is crucial to promoting clean energy and high-end
manufacturing. With the popularization of intelligent and green
technologies, the copper electrolysis industry will usher in a
new era of higher efficiency and sustainability.