In the process of copper electrolysis production, the problem of copper particle residue has
been a pain point that affects product quality and production efficiency. The traditional
cleaning method relies on manual operation, which is not only inefficient, but also has safety
hazards. With the progress of industrial automation technology, copper particle automatic
cleaning equipment has gradually become the standard equipment for copper electrolysis
enterprises. This article will analyze the working principle of this type of equipment, and
share the key maintenance techniques to help manufacturers realize cost reduction and
efficiency.
The necessity of automatic copper particle cleaning
equipment
Electrolytic copper production process, the electrolyzer will continue to produce 0.5-2mm diameter
copper particles. If these tiny particles are not removed in time, it will lead to three major problems: first,
the deposition of uneven copper layer on the surface of the cathode, resulting in substandard product
surface quality; second, increase the resistance of the electrolyte, resulting in an increase in energy
consumption of about 5-8%; third, accelerate the corrosion of the electrode, shortening the service life
of the equipment. The data of a large smelter shows that after using the automatic cleaning equipment,
the product qualification rate is increased by 12% and the annual maintenance cost is reduced by 23%.
Core working principle revealed
Modern automatic cleaning equipment adopts modular design, mainly contains four major functional systems:
Intelligent identification system
Equipped with a high-precision capacitive sensor array, it can monitor the concentration of copper particles in the
electrolyzer in real time. When the value exceeds the set threshold (usually 50-80ppm), the system automatically
triggers the cleaning program. Adopting adaptive algorithm, it can dynamically adjust the detection sensitivity
according to the electrolyte temperature and flow rate.
Vacuum suction device
Equipped with titanium alloy suction nozzle, corrosion resistance up to PH1-PH3. Two-stage cyclone separation
structure realizes gas-solid separation, copper particle collection efficiency up to 99.6%. The suction power can be
automatically adjusted according to the amount of particles, and the energy consumption is 40% lower than
traditional equipment.
Self-cleaning filtration system
Multi-layer gradient filter design, the front stage 100 mesh stainless steel filter intercepts large particles, the back
stage ceramic membrane filter element (pore size 0.1μm) filtration of fine impurities. Unique backwashing
technology automatically cleans the filter mesh every working cycle to avoid the risk of clogging.
Intelligent control system
Integrated PLC+IoT module supports remote monitoring and parameter setting. With fault self-diagnosis function,
it can recognize 21 common fault types and provide real-time warning via SMS/APP.
Golden rule of daily maintenance
Scientific maintenance can extend the service life of the equipment for 3-5 years, it is recommended to implement the
following standardized process:
1. three-tier inspection system
Operators check every shift: vacuum pressure gauge readings (normal value -0.05 ~ -0.08MPa), collection bin
level (no more than 80% volume)
Weekly inspection by technician: sensor calibration, seal wear (thickness <2mm need to be replaced), screen integrity
Engineer monthly inspection: motor bearing lubrication (filling NLGI2 grade lithium grease), circuit insulation test (≥500MΩ)
2. Replacement cycle of key components
Ceramic cartridge: mandatory replacement when the accumulated working hours are 2000 hours or the
differential pressure > 0.15MPa
Suction nozzle assembly: every 6 months to check the titanium alloy wear, the inner diameter expansion
of more than 0.5mm that is replaced
Drive belt: quarterly check the tension, cracks immediately replaced.
3. Sudden failure response guide
Decrease in suction power: first check the blockage of filter, then check the wear of vacuum pump carbon plate.
Sensor false alarm: use standard solution (containing 80ppm copper particles) for calibration test.
Abnormal vibration: immediately stop the machine to check the motor base bolt and impeller dynamic balance.
Four main points of equipment selection
When selecting equipment, we need to focus on the following considerations:
Processing capacity to match the volume of the electrolyzer (recommended to leave a margin of 20%)
The material should be resistant to 60℃ acidic electrolyte (TA2 titanium is recommended).
The energy consumption ratio should be below 0.8kW-h/m³.
Maintenance channel design is easy to replace the filter element and other wear parts
V. Industry technology development trend
The latest R&D direction focuses on intelligent upgrading:
Introducing AI visual recognition technology to realize copper particle shape classification statistics
Developing online analysis module for electrolyte composition, and adjusting cleaning strategy in a
linked manner.
Applying magnetic fluid sealing technology to extend the maintenance cycle to 6,000 hours.
Conclusion
The application of automatic copper particle cleaning equipment marks a key step towards the intelligent
transformation of copper electrolysis production. Through in-depth understanding of the operation
mechanism of the equipment and the establishment of a scientific maintenance system, manufacturers
can not only ensure the efficient and stable operation of the equipment, but also continue to enhance the
competitiveness of their products. It is recommended that enterprises regularly organize technical
exchanges with equipment manufacturers to obtain the latest upgrading solutions in a timely manner
and seize the first opportunity in the industry change.