The non-ferrous metal smelting industry is experiencing a profound change driven by
automation technology, among which the intelligent upgrade of electrolytic copper
separation process is particularly remarkable. Through the integration of Internet of
Things, big data analysis and advanced control algorithms, the traditional copper
electrolysis production mode is being redefined, which not only realizes breakthroughs
in purification efficiency and energy consumption control, but also builds up an
all-process traceable quality management system.
Technological breakthrough of intelligent monitoring system
Modern copper electrolysis workshop has built up a three-dimensional data collection network. In the
key area of electrolyzer, 28 types of sensing devices are deployed, such as corrosion-resistant pH sensor
(accuracy ±0.02), multi-spectral metal ion concentration meter (detection limit 0.1ppm) and micro-pressure
difference flow meter. These devices upload data at a frequency of 5 times per second, forming a dynamic
digital mirror of the electrolysis process.
Innovation in the Application of Precision Control Technology
In terms of current density regulation, the intelligent rectifier system adopts pulse width modulation (PWM)
technology to realize stepless adjustment within the range of 0-6000A. Through the dynamic impedance
matching algorithm, the system can automatically compensate for voltage fluctuations according to the
pole pitch change (±2mm), which improves the tank voltage stability to 99.7%. This innovation reduces
the DC power consumption of tons of copper to 2,150kWh, reaching an industry-leading level.
The cathodic deposition control module introduces machine vision technology, and a high-precision
industrial camera (5μm resolution) continuously monitors the growth status of copper foil. When
abnormal grain size or dendrite risk is recognized, the system adjusts the current waveform within
0.8 seconds, and combined with pulse reverse electrolysis technology, reduces the surface
roughness of copper cathode to less than Ra0.8μm, which significantly improves the product grade.
Equipment Full Life Cycle Management System
Electrode Health Diagnosis System constructs an evaluation model containing 15 dimensions such as
temperature field, stress distribution, corrosion rate, etc. through multi-parameter fusion analysis.
Adopting ultrasonic guided wave detection technology, the remaining life of anode plate can be
evaluated without stopping the machine, and the prediction accuracy reaches 94%. The supporting
automatic pole-changing device carries a six-axis robotic arm, which, together with the laser
positioning system, compresses the pole-changing operation time to 3 minutes/group, with a
positioning accuracy of ±0.2mm.
Intelligent Cleaning System for Electrolysis Tanks breaks through the traditional high-pressure water
washing mode, and develops ultrasonic cavitation synergistic chemical cleaning process. By adjusting
the 20-40kHz frequency conversion ultrasonic wave, together with the environmentally friendly
cleaning agent, the deep cleaning can be completed within 45 minutes, and at the same time
reduce 90% of wastewater emissions. This technology extends the annual effective working
time of the electrolyzer to 8600 hours.
Green Production and Resource Recycling
The energy management hub integrates process parameters and grid load data, and uses dynamic
planning algorithms to optimize electricity consumption strategies. In the valley of electricity price,
the production intensity is automatically increased by 5%-8%, and with the flywheel energy storage
device to smooth out the load fluctuation, the comprehensive energy consumption of tons of
copper is reduced by 18%. The waste heat recovery system converts the waste heat of electrolyte
above 80℃ into heat energy of drying process through a three-stage heat exchange device,
saving 12,000 tons of steam annually.
In terms of resource recycling, the intelligent stripping unit adopts vacuum adsorption and flexible
stripping technology, resulting in a 99.5% yield rate of starting pole pieces. The anode sludge
treatment line is equipped with an X-ray sorting machine, which recognizes the precious metal-rich
area through dual-energy imaging, increasing the gold and silver recovery rate to 98.3%. The
wastewater treatment unit introduces electrochemical oxidation process, with copper ion
removal efficiency of 99.99%, and the reuse water quality reaches GB/T 19923-2005 standard.
Safety Protection and Standardized Construction
The multi-layer safety protection system contains 132 interlocking control points, covering 23 types of
risk scenarios such as gas leakage and temperature overrun. Explosion-proof hydrogen monitor
(detection limit 0.1% LEL) is linked with the emergency inerting system, which can start the nitrogen
override procedure within 0.3 seconds. Tank voltage intelligent monitoring module adopts fiber-optic
isolation technology, detects short circuit between poles in real time and triggers millisecond
power failure protection.