节能型铜粉电解槽内流体流动行为及调控机制

High energy consumption of electrolysis process in production of copper powder has become the major bottlenecks to the development of the enterprises, which rooted in the concentration polarization of copper ions between the negative plate and electrolyte when copper powder is prepared at low copper ions concentration (8-12g/l) and high current density (1400-1600A/m2). Moreover, circulation way of electrolyte in traditional electrolysis cell is not beneficial to mass and heat transfer, which would raise the cell voltage and reduce the current efficiency. These all lead to electrolysis becomes the biggest energy consumption process in copper powder production. Therefore, the key to save energy consumption in electrolytic deposition process lies in the elimination of concentration polarization, which will depend on the breakthrough in traditional feeding method with electrolyte entering at bottom and leaving at top. The electrolysis process will be studied in order to eliminate concentration polarization of copper ions with immovable property of copper powder, same major structure and electrode dimension of electrolytic cell. Meanwhile, combining the numerical simulation with the experiments, the effect of newly feeding inlet pattern on energy consumption of the electrolysis process will be studied. Flow behavior and change rule of electrolyte in energy saving electrolytic cell will be revealed. The inherent link between energy consumption and circulation way of electrolyte and flow pattern between anode and cathode will be illuminated. Finally, the regulating mechanism of fluid flow in energy saving electrolytic cell will be established, which will provide theoretical guidance for energy saving in electrolysis process of copper powder production, which will also provide lessons for improving energy conservation in electrolysis industry of copper,zinc, lead and so on.

铜粉电解过程能耗过高已成为制约企业发展的主要瓶颈，其根源在于在低铜离子浓度（8-12 g/l），大电流密度（1400-1600A/m2）条件下制备铜粉，极易在阴极板/电解液界面产生Cu2+浓差极化问题，且现行电解槽内电解液的流动方式，不利于传质，导致槽电压升高，电流效率下降。因此，突破电解槽传统的“下进上出”进液方式，消除浓差极化已成为铜粉电解工序节能降耗的关键。本项目拟以铜粉电解过程为研究对象，从减少浓差极化的角度出发，在不改变电解槽主体结构和尺寸以及铜粉质量的前提下，综合采用实验研究和数值模拟相结合的方法，系统研究节能型铜粉电解槽新型进液方式变化对电解能耗的影响；阐明进液方式与极间流场形态和能耗的内在关系；揭示电解液在节能型电解槽内流动行为及变化规律；建立节能型铜粉电解槽内流体流动行为调控机制，为铜粉电解过程中的节能降耗提供理论指导，也可对铜、锌等电解工业现行电解槽节能改造提供借鉴。

铜粉电解过程能耗过高已成为制约企业发展的主要瓶颈，其根源在于在低铜离子浓度，大电流密度条件下制备铜粉，极易在阴极板/电解液界面产生Cu2+浓差极化问题，因此，突破电解槽传统的“下进上出”进液方式，消除浓差极化已成为铜粉电解工序节能降耗的关键。本课题以铜粉电解过程为研究对象，从减少浓差极化的角度出发，在不改变电解槽主体结构和尺寸以及铜粉质量的前提下，综合采用实验研究和数值模拟相结合的方法，系统研究了节能型铜粉电解槽新型进液方式变化对电解能耗的影响，阐明了进液方式与极间流场形态和能耗的内在关系；揭示了电解液在节能型电解槽内流动行为及变化规律。节能型电解槽内电解液流动流动方式的改变有助于消除死区，且溶液浓度均匀；电解液流动流动方式的改变有助于节能降耗，不仅为铜粉电解过程中的节能降耗提供了理论指导，而且可对铜、镍、铅、锰等电解工业现行传统电解槽节能改造提供了借鉴。.研究取得如下成果：1)根据电解过程电解液传输行为的特点，建立了描述电解液流动与传质以及漂浮阳极泥运动轨迹的数学模型。2）基于所建立的铜粉电解过程流动与传质数学模型开展数值模拟研究，采用工业电解槽的实测数据验证了数学模型及求解方法的正确性，并获得了电解过程湍流自然对流条件下的特征数方程。3）基于电解液传输行为的数学模型，研究了极间射流对高电流密度下电解液流动与传质以及漂浮阳极泥运动轨迹的影响。4）利用具有平行流进液装置的新型电解槽，综合研究了电解液进液方式对槽电压、电流效率、电解能耗和铜粉性能的影响；并通过响应面分析构建了铜粉电解直流电耗的预测模型以及调控方法。.申请国家发明专利3项，已授权2项，授权实用专利3项；在国内外发表论文8篇，其中SCI3篇，EI1篇，中文核心4篇，会议报告5次，获得中国有色金属协会科技进步三等奖1项，通过本项目研究培养了博士研究生1名，研究生2名，并转让技术成果1项，正进一步与其他相关企业公司共同推进新技术的转让工作。