To Improve Product Performance, Production Efficiency, and Service Life
1. Introduction
Designing a stainless steel cathode requires attention to four key details that ensure optimal performance, increased production efficiency, and extended service life. These four considerations are:
- The bottom of the blade should have a V-shaped groove.
- The edge strips on both sides of the blade should be equipped with tension rods.
- The width and height of the blade of the stainless steel cathode should be larger than the dimensions of the anode blade.
- The distance between the liquid level line and the weld of the stainless steel cathode (where the conductive beam meets the blade) should ideally be 150mm±50mm.
2. The Bottom of the Blade Should Have a V-Shaped Groove Design
The V-shaped groove at the bottom of the blade is a crucial design feature in modern stainless steel cathodes. Traditionally, a wax coating was applied to the blade’s bottom to prevent the cathode copper sheet from sticking during stripping. However, the wax coating process had its drawbacks—it required reapplication after each stripping, adding maintenance and operational costs.
By milling a V-shaped groove at the bottom of the blade, the need for wax is eliminated. This simple modification allows the cathode copper sheet to be easily stripped from the blade, preventing it from sticking. The V-shaped groove ensures that the cathode copper sheet detaches smoothly every time without requiring re-coating, reducing downtime and increasing overall production efficiency.
Advantages:
- One-time solution: No need for waxing after every stripping.
- Reduces procurement and maintenance costs for customers.
- Enhances production efficiency and eliminates the need for waxing devices.
3. The Edge Strips on Both Sides of the Blade Must Be Equipped with Tensioning Rods
The edge strips on both sides of the blade are designed to enhance the durability of the cathode. To install the edge strip correctly, the groove of the edge strip must be aligned with the blade edge. Using a rubber hammer, the edge of the blade is inserted into the edge strip groove, followed by placing the tension rod into the circular groove on the outer side of the strip. Once in place, the tension rod works on a lever principle to tightly secure the strip around the blade.
This design improves the corrosion resistance of the edges, which is vital for extending the service life of the cathode. The additional tension rods ensure that the edge strip stays in place, enhancing the cathode’s overall structural integrity.
Advantages:
- Improved corrosion resistance on the edges of the blade.
- Increased service life of the cathode.
- Reduced operational costs by minimizing wear and tear.
- Lowers the need for spare cathode purchases, thus reducing procurement costs.
4. Is the Width and Height of the Blade of the Stainless Steel Cathode Longer than the Blade Dimensions of the Anode?
In our design, the blade of the stainless steel cathode is deliberately made larger than the anode blade to improve the quality of the cathode copper sheet. Typically, the deposition area of the cathode blade is 30mm wider and 35–40mm taller than that of the anode blade. This extended dimensions ensures a more uniform thickness of the deposited cathode copper sheet, preventing thicker areas at the edges and bottom, which can be difficult to strip off during the electrowinning process.
By increasing the width and height of the cathode blade, we promote a smooth and even deposition of copper, reducing operational issues during the stripping process.
Advantages:
- More uniform thickness of the copper sheet.
- Easier and more efficient stripping process.
- Prevention of thick edges that could interfere with stripping.
5. Distance Between the Liquid Level Line and the Weld of the Stainless Steel Cathode
The distance between the liquid level line and the weld (where the conductive beam meets the blade) is a critical factor in preventing corrosion. To avoid acid mist corrosion of the weld, this distance should be no less than 100mm. However, since the liquid level can fluctuate, a design range of 150mm to 160mm is recommended to accommodate for these changes.
This design ensures that the weld remains well-protected from corrosive acid mist, thereby prolonging the cathode’s life span. Under normal working conditions, a properly designed stainless steel cathode can last up to 15 years in copper electrowinning applications.
Advantages:
- Protects the weld from corrosion by acid mist.
- Maximizes the service life of the stainless steel cathode.
- Reduces maintenance and replacement costs for the customer.
6. Conclusion
The four key details in designing a stainless steel cathode—V-shaped grooves at the blade’s bottom, tension rods in the edge strips, larger blade dimensions compared to the anode, and optimal distance from the liquid level to the weld—are all designed with one goal in mind: improving the cathode’s performance, production efficiency, and service life. These design enhancements reduce operational costs, prevent premature wear, and increase the overall lifespan of the cathode, making it a more cost-effective solution for copper electrowinning plants. By addressing these critical aspects, we ensure that our stainless steel cathodes provide long-term value and reliability to our customers.
