The final step：Gap Filling, Capping Board Installation, and Precautions to Avoid Prohibited Operations
In our previous article https://copperepc.com/how-to-install-te-electrowinning-cells/,
1. Gap filling between electrowinning cells
Once all electrowinning cells are precisely leveled and aligned, the next crucial step is to fill the gaps between the cells. This ensures that the cells remain firmly in place and prevents any movement that could disrupt the entire system.
Step-by-Step Process:
- Installing Polyurethane Foam Rods: Start by placing polyurethane foam rods between the cells. These rods play a key role in securing the polymer mortar and maintaining the correct position as it solidifies. The foam rods ensure the mortar fills all the necessary gaps evenly.
Referencing Drawings and Guidelines: Carefully follow the provided technical drawings and guidelines for gap filling to ensure the correct materials and techniques are used throughout the process. This ensures that the filling is both effective and aligned with the intended design specifications.
Avoiding Residue on Cell Surfaces: It is important to prevent any excess filling material from staining or leaving residue on the top surface of the cells. This ensures that the cells maintain their intended integrity and prevents any interference with subsequent operations.
Step 1：Laying Foam Rod
Step 2：Making the Filling Hopper
Step 3：Preparing the Resin
Step 4：Measure Cross Section Width of Lead Cladding
Step 5：Add the Curing Agent into the Resin
Step 6：Stirring Well by Portable Agitator
Step 7：Stirring Until the Resin Changes Color
Step 8：Preparing Quartz Sand
Step 9：Adding Quartz Sand into the Stirred Resin and Stirring Well
Step 10：Slowly Pouring The Resin Mortar Into The Filling Hopper So That It Can Pass Through The Gap Of The Filling Hopper And Fill Into The Gaps Between The Cells.
Step 11：Surface Leveling
Step 12：Filling Completed
Step 13：Cutting Off the Excess Part of the Foam Rod’s End
Step 14：Using the Mortar to Seal the End of the Foam Rod
2. Installation of cell top furniture (capping board)
Step-by-Step Process:
Installing End Cells First: The installation begins with the four end cells. There are three types of capping boards: left end, right end, and intermediate. Each capping board must be installed on the correct corresponding end cell. This step is crucial to ensure proper alignment and functionality.
Installing Intermediate Cells: After the end cells are capped, proceed with installing the capping boards on the intermediate cells. This step requires careful attention to the placement of the capping boards to ensure that all components are securely fitted.
Final Checks and Accuracy Measurements: Once all the capping boards are installed, conduct thorough checks to measure the accuracy of the installation. This final inspection ensures that the capping boards are properly aligned, providing an effective seal and protecting the cells from external factors.
3. Prohibited operations
Turning the Cell Over: Never place the electrowinning cell on its side or turn it over. This can cause internal misalignment, damage to the cell structure, and can result in safety hazards.
Stacking Cells on Top of Each Other: Avoid placing one cell on top of another during the installation process. Doing so can cause undue stress on the cells, leading to deformation or damage to critical components.
Improper Lifting Procedures: When lifting the cells, always use a sling to support them. Never use the cell lifting beam for this purpose, as improper lifting can cause strain and potential damage to the structure of the cells.
Impact Damage: Avoid any impact that may cause the cells to collide with one another, the ground, the foundation, or other structures. Such collisions can lead to structural damage and significantly affect the performance of the cells.
Uncontrolled Handling: Any uncontrolled or careless handling of the cells during installation could result in damage to the anti-corrosion layer or other critical components, creating operational hazards that may affect the entire system.
Need Help with Electrowinning Cell Storage and Installation?
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