In the field of nonferrous metal smelting, the intelligent application of copper
and zinc electrodes is triggering a silent revolution. With the deep integration of
the Internet of Things, edge computing and other new-generation information
technology, the traditional electrode system is experiencing a leapfrog transformation
from mechanization to digitalization, which not only reconstructs the production
process of hydrometallurgy, but also reshapes the efficiency standard of the whole industry.
Intelligent evolution of process control system
Modern hydrometallurgical plants have realized the digital control of the whole process of
electrode system. Through the distributed sensor network deployed in the electrolyzer area,
the system is capable of real-time collection of 27 key parameters, such as electrolyte
temperature, metal ion concentration and PH value. Relying on the dynamic model established
by adaptive algorithms, the system can accurately predict the optimal current density under
different working conditions, transforming traditional empirical operation into data-driven
intelligent decision-making.
In the electrolytic refining process, the intelligent control system realizes millimeter-level
response to electrode reaction through the high-frequency current adjustment module
(with an adjustment accuracy of ±0.5A). Combined with machine vision technology, the
system can automatically identify the crystallization morphology of the electrode plate, and
when abnormal dendrite growth is detected, it can trigger the current gradient adjustment
program within 3 seconds, reducing the risk of short circuit by 83%. This real-time feedback
mechanism increases the electrolysis efficiency to 94.6%, 11 percentage points higher than
the traditional process.
Construction of equipment health management system
The new electrode intelligent diagnostic system adopts multi-physical field coupling analysis
technology to construct a digital twin model of the electrode state by means of 12-dimensional
characteristic parameters such as vibration, temperature and impedance spectrum. The fault prediction
algorithm built into the system can warn of potential problems such as electrode corrosion and
coating peeling 72 hours in advance, with an accuracy rate as high as 92%. Operation and maintenance
personnel can view the electrode health index in real time through the mobile terminal to realize
preventive maintenance.
In response to the efficiency bottleneck in traditional electrode replacement operations, the automated
electrode changer adopts a six-axis robotic arm and laser positioning technology, compressing the
electrode plate replacement time to 4.5 minutes/group. Equipped with an intelligent clamping system
that can automatically compensate for the deformation of the electrode plate, the installation and
positioning error is controlled within ±0.3mm. This innovation improves the effective operating time
of the equipment to 98%, and reduces the loss of unplanned downtime by about 1,200 hours per year.
Energy Efficiency Optimization and Resource Recycling
Intelligent Electrolysis Power Supply System adopts the third-generation IGBT module with adaptive
resonance topology, which improves the power conversion efficiency to 97%. Dynamic power factor
correction technology enables the system to be intelligently adjusted in the range of 0.95-1.0, with
annual power saving of up to 3.8 million degrees. The waste heat recovery device converts the waste
heat from the electrolysis tank into steam energy through plate heat exchanger, realizing the
system-level energy closed loop.
System Safety and Standardized Construction
Multi-layer protection system integrates DCS safety instrumentation system and sets 128 safety interlocking
points. Explosion-proof gas monitor can simultaneously detect 6 kinds of dangerous gases such as
hydrogen, chlorine, etc., and the alarm response time is ≤0.5 seconds. Emergency protection system
can complete the whole line power failure within 0.3 seconds and start the nitrogen override protection
program when abnormal tank voltage is detected.
Standardized data interface supports OPC UA, MQTT and other industrial protocols to achieve seamless
connection with factory MES and ERP systems. Production process data is uploaded to the cloud platform
at a frequency of 15 seconds/time, forming a complete quality traceability chain. The system complies
with IEC 61508 Safety Integrity Level SIL3 certification and passes ISO 50001 energy management
system certification.
At present, the non-ferrous metallurgical industry is standing at the key node of intelligent transformation.
The technological breakthrough of copper and zinc electrode control system not only brings geometric
improvement of production efficiency, but also creates a new paradigm of green manufacturing.