In copper electrolysis, the environment is highly corrosive and operationally demanding. Titanium, known for its excellent corrosion resistance, high strength-to-weight ratio, and long service life, is widely used across nearly all major equipment and components. This article outlines how titanium supports better performance, longer durability, and lower costs in copper electrolysis plants.
1. Titanium in Core Equipment Application
Electrolytic Cells
Titanium is a reliable lining or structural material for electrolytic cells due to:
Excellent resistance to acid electrolyte corrosion
Stable mechanical strength under long-term operation
Preventing leakage and prolonging cell life
Electrolyte Storage and Circulation
Titanium tanks and pipelines ensure the chemical stability and purity of the electrolyte. It eliminates contamination risk during storage and transfer, improving final copper quality.
Supporting Equipment
Several auxiliary systems in copper electrolysis also benefit from titanium construction:
-
Pumps: Titanium wetted parts resist acidic erosion during continuous electrolyte circulation.
-
Wash Towers: Used for gas purification, titanium ensures structural longevity in acid mist environments.
-
Heat Exchangers: High thermal conductivity and chemical stability make titanium ideal for temperature control.
-
Filters: Maintain electrolyte clarity without being compromised by corrosion.
Valves, Piping, and Connectors
Titanium is widely used in flow systems for:
Long-term acid resistance
Leak-proof performance
Reduced maintenance frequency
2. Titanium Cathode Starter Plates (Titanium Mother Plates)
One of the most valuable applications of titanium in copper EW is in starter cathodes, where titanium significantly outperforms traditional copper.
Structure
Titanium sheet body
Titanium–copper composite hanger bar
Precision welding ensures conductivity and mechanical strength
Advantages
| Parameter | Copper Starter Plate | Titanium Starter Plate |
|---|---|---|
| Service Life | 6–7 years | Up to 20 years |
| Weight | Heavy | 50% lighter |
| Peeling Productivity | Normal | +25–30% improvement |
| Sheet Yield Rate | 75–80% | 98%+ |
| Separation Agent | Required | Not required |
Titanium forms a stable oxide layer that acts as a natural separating film, making pre-coating unnecessary and improving production cleanliness.
3. Titanium in Sulfate and Byproduct Handling Systems
Titanium is widely used in equipment that handles sulfuric acid and sulfate-rich streams, such as:
Vacuum Evaporators: Resistant to vacuum pressure, heat, and acids.
Crystallizers: Provide consistent, corrosion-free cooling for solid sulfate recovery.
Serpentine Heaters: Offer efficient, safe heating with no material degradation.
These components are crucial for recovering and managing byproducts in a clean, closed-loop operation.
4. Long-Term Economic and Operational Benefits
Although titanium has a higher upfront cost than copper or stainless steel, its long-term benefits far outweigh the initial investment.
Lifecycle Cost Comparison
A case study showed that over a 9-year operation period, the total cost of using titanium starter plates was just 21.68% of that of copper—considering fewer replacements, less downtime, and improved output.
Operational Efficiency
Reduced labor intensity due to lighter weight
Fewer shutdowns for repair or replacement
Increased automation potential due to long-term material stability
Conclusion
Titanium plays a vital and growing role in the copper electrolysis industry. From structural parts to critical cathode systems, its resistance to corrosion and mechanical fatigue makes it ideal for modern plants aiming to reduce maintenance, improve output quality, and support automation.
At PRS, we help clients integrate titanium into their copper electrolysis systems where it makes the most sense—delivering long-term value and performance.
