US3809902A - Method and apparatus for detecting incipient short circuit conditions in electrolytic cells - Google Patents

Method and apparatus for detecting incipient short circuit conditions in electrolytic cells Download PDF

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Publication number
US3809902A
US3809902A US00315411A US31541172A US3809902A US 3809902 A US3809902 A US 3809902A US 00315411 A US00315411 A US 00315411A US 31541172 A US31541172 A US 31541172A US 3809902 A US3809902 A US 3809902A
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path
cells
scan
electrolytic
traverse
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US00315411A
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D Cofer
B Betterton
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Southwire Co LLC
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Southwire Co LLC
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Priority to US00315411A priority Critical patent/US3809902A/en
Priority to FI2547/73A priority patent/FI62600C/fi
Priority to FR7337193A priority patent/FR2210770B1/fr
Priority to TR18439A priority patent/TR18439A/tr
Priority to IT53379/73A priority patent/IT1008587B/it
Priority to ES421439A priority patent/ES421439A1/es
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    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
    • C25C7/00—Constructional parts, or assemblies thereof, of cells; Servicing or operating of cells
    • C25C7/06—Operating or servicing
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/50—Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections
    • G01R31/52—Testing for short-circuits, leakage current or ground faults
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H1/00—Details of emergency protective circuit arrangements
    • H02H1/0061—Details of emergency protective circuit arrangements concerning transmission of signals
    • H02H1/0069—Details of emergency protective circuit arrangements concerning transmission of signals by means of light or heat rays

Definitions

  • This invention relates in general to the detection of short circuit conditions and in particular to the detection of incipient short circuit conditions as found in electrolytic cells used in metal refining operations.
  • the art of electroplating in additionto being useful for the application of a relatively thin outer metallic coating on a base or substrate metal, is also of known utility in the refining of metals such as copper.
  • relatively impure copper anodes are prepared by a conventional casting process and are placed in tanks containing a suitable electrolytic solution such as copper sulphate.
  • the tanks are I also provided with suitable cathodes, which typically may consist of relatively pure, thin copper starter sheets.
  • the relatively impure copper anodes and the relatively pure copper cathodes are connected to a suitable source of electrical current, and the copper is plated from the anodes onto the so-called starter sheets, resulting in cathode sheets of relatively pure copper which are removed from the electroplating tanks for subsequent use.
  • the electrolytic refining of copper or other metals at production quantities generally requires large numbers of electr'olytic'cells each containing a number of anodes and cathodes, and the proper operation of each cell depends upon the accurate control of the electric current density between the various anodes and cathodes. It is known to those skilled in the art that short circuits can occur between an adjacent anode and cathode, and such short circuits create a preferential path of current flow in the localized area of the short circuit which raises the current density at such location to a level which is greater than the optimum desired current density.
  • Such short circuits can occur from a number of causes, such as inaccurate initial placement of an ad.- jacent anode, and cathode, buckling of the relatively thin cathode starter sheet, or the growth of copper nodules growing from a cathode to touch an adjacent anode during the process of electrolytic refining.- Whateverthe cause of the short-circuit condition, themetallic cathode which is produced as aresult ofa short circuit fails to have the desired metallurgical properties, withthe result thatsuch unacceptable cathodes must be remelted into relatively impure copper anodes and again. subjected to the electrolytic refining process.
  • the gauss meter which those skilled in the art will recognize as an instrument for measuring the field surrounding a conductive member through which electrical current'is flowing, is similarly used in prior-art inspection of electrolytic refining tanks to measure the current flowing through the anode and cathode plates.
  • Prior-art gauss meter measuring techniques require the services of an inspector who manually passes the gauss meter over the anode and cathode plates of each individual tank in an attempt to detect the existence of an abnormal current condition associated with one or more plates.
  • short-circuit detection techniques of the prior art require a high level of operator expertise. to evaluate the meter readings of a voltmeter'and/or a gauss meter to determine whether the particular meter readings actually indicate a short-circuit condition.
  • inspection techniques are generally capable of detecting only a short circuit which has been in existence for at least 6 to 12 hours, at the earliest, depending upon the current density, thus requiring the cathode to be reworked as described above with attendant loss of electrical energy and work in process.
  • incipient short circuit means a short circuit condition which exists in an electrolytic cell but which has not yet developed to a magnitude where the short circuit condition can be detected with conventional gauss meter measurement.
  • FIG. 1 is a schematic isometric view of a cell scanning operation according to an embodiment of the present invention
  • FIG. 2 is a plan view of a metal refining tankhouse installation equipped for cell scanning according-to the disclosed embodiment of the present invention
  • FIG. 3 is a schematic view of the readout portion of the disclosed embodiment.
  • FIG. 4 is a photographic reproduction of an actual facsimile recorder printout produced by the disclosed embodiment of the present invention and showing various anomolous cell conditions, as described in detail below.
  • incipient short-circuit conditions are detected according to the present invention by scanning an electroplating cell, or a plurality of such cells, with a heat-responsive sensor such as an infrared detector at a rate of scan and scan traverse selected to i provide information of thermal abnormalities resulting from the abnormal current density which is caused by incipient short circuits.
  • a heat-responsive sensor such as an infrared detector
  • an infrared scanner is repetitively swept across the cell area undergoing investigation while simultaneously being traversed along a direction transverse to the direction of scan, with the scan and traverse rates being adjusted to provide substantially contiguous scan paths along the surfaces of the 13.
  • Each of the cathodes 12 is connected to a negative electrical bus 14, while each of the anodes 13 is correspondingly connected to a positive electrical bus 15.
  • the tank 11 is substantially filled with an appropriate electrolyte 16 which, in the case of a copper refining cell as aforementioned, may appropriately be copper sulphate.
  • the disclosed embodiment of the present invention is in the context of a copper refining operation, it will be apparent to those skilled in the art that the present invention can be used in other metal refining operations, as well as in electroplating operations generally, to detect the presence of incipient short-circuit conditions therein.
  • the reference to a cooper refining operation is by way of example only, and is without intent to limit the present invention to use in the context of copper refining.
  • An infrared scanner 20 is suspended from or otherwise mounted on a carrier 2l'mounted for transverse movement along a support member 22 which is, in turn, mounted for selective controlled movement along the path 23 corresponding to the lateral direction of the cell tank 11.
  • the support member 22 may advantageously be provided by a travelling bridge crane which is usually present in such a facility and which travels along rails (not shown in FIG. 2) suspended above the sides of the bay or other work area in which a plurality of the cells 10 are positioned.
  • Travelling bridge cranes typically have a hoist carrier which is capable of transverse motion in a direction 24 parallel to the supportmember 22, and this transverse motion 24 is useful for a purpose described below.
  • the use of an existing crane to support the infrared scanner 20 is optional, inasmuch as the infrared scanner can alternatively be provided with a separate and independent support apparatus.
  • the lateral directional movement of the infrared scanner relative to the 'cell tank, in the described embodiment of the invention is determined by the existing positions of the cells and the bridge crane.
  • the scanner may be moved in any suitable direction which enables the desired surface area of the cells to be scanned, including scanner movement at a right angle to the movement depicted in FIG. 1.
  • the infrared scanner 20 used in the disclosed embodiment of the present invention is of the type which repetitively sweeps an instantaneous field of view 25 along a path 28 defined by the predetermined scanning are 26.
  • Infrared scanners of this type are known to those skilled in the art, and typically include a rotating mirror which reflects the radiation collected from the field of view 25 through an optical system for focusing onto an infrared detecting element, whereat the instantaneous level of detected infrared energy is converted to an analog electrical signal.
  • Infrared scanning apparatus of this type is available, for example, from the Barnes Engineering Company of Stamford, Conn.
  • the scanning are 26 is preferably at least of sufficient magnitude, considered with the elevation 27 of the infrared scanner 20 above the surface of the cell 10 being scanned, which allows the entire length of at least one cell to be scanned.
  • a scanning arc 26 of 90 is sufficient to scan a tank 11 having a length of 50 ft., with the scanner 20 positioned at an elevation 27 of 25 ft. above the tank.
  • a typical state-of-the-art infrared scanner 20 thus positioned will produce an instantaneous field of view 25 of approximately 0.25 inch resolution at the tank surface directly below the scanner.
  • the present invention has the ability to detect thermal abnormalities on a minimum length of cell metallic member such as an anode, a cathode, or the supports therefor, which minimum length usually has a dimension of at least one inch.
  • An incipient short-circuit is caused by the occurrence of some abnormal conditionwhich causes a localized current density which is somewhat greater than the nominal current density in locations surrounding the thermal abnormality.
  • the'electrolytic refining process may cause a nodule of refined copper to commencegrowing outwardly from a cathode to an adjacent' anode.
  • the current density at the location of nodule contact is increased and, as the growth of the nodule continues, the abnormally-high current density continues to increase.
  • the aforementioned increased current density at the nodule location causes a relative temperature increase or hot spot, and detection of this hot spot at the earliest practical time permits Iprompt corrective measures to be taken to minimize'loss of production and wasted electricity.
  • FIG. 2 there is shown a plan view of a typical bay of atankhouse for the electrolytic-refining of a metal such as copper.
  • the bay shown generally at 33, contains a number of electrolytic cell sections 42, with each such tank section containing a plurality of cells which may be substantially similar to the cells 10 of FIG. 1.
  • the cell sections 42 are arranged in four rows, as shown in FIG. 2.
  • the support member 22 is the cross beam of a travelling crane mounted for powered movement along the two-rails 34 and 35, and the scanner carrier 21 is mounted for transverse movement along the travelling crane.
  • the signal output from the infrared scanner, along with control signals and operatingpower required of the scanner, are supplied by a suitable cable arrangement 36 supported in a festoon system or any other arrangement which is appropriate to permitting the necessary travel of the crane.
  • a telemetry or similar system may be used in place of cable arrangement 36.
  • a pair of switches 37 and 38 Positioned at opposite ends of the crane rail 35 is a pair of switches 37 and 38 which are actuated by movement of the crane at the switch positions and which provide signals denoting the beginning and the end of a scanning pass over a particular row of tank sections.
  • a plurality of pulse switches 39a-39f are also positioned adjacent the crane rail to be actuated by passage of the crane therealong, with each such 'cable 40, while the outputs of the pulse switches 39a-39e are supplied to a control cable 41; these two control cables, along with the cable 36 connected to the infrared scanner, are supplied tothe display apparatu s as shown on FIG. 3..
  • the input signal to the facsimile recorder 44 is the electrical signal provided by the infrareddetecting element in the scanner 20, and this input signal is identified on FIG. 3 as the video signal supplied on the cable 36.
  • the facsimile recorder 44 includes a mechanical drive mechanism which moves recording paper at, a constant predetermined rate past a recording device which traverses the width of the recording paper in synchronism with the repetitive scanning of the field of view 25 provided by theinfrared scanner 20. Since the video signal supplied to the recorder 44 is function of the temperature of each scanned location on the surface of a tank 1 1, the resulting recording 45 may be likened to a thermal map of the tank surface. 1
  • the video signal and position sync signal may also be supplied along lines 36, 46a and 4ll, 46b, respectively, to a cathode ray tube (CRT) display 47, if desired, which can be operated to provide an instantaneous visual display of the thermal signal provided by each scan path 28 across a cell 10.
  • CTR cathode ray tube
  • the crane 22 and the carrier 21 are initially positioned as shown in FIG. 2.
  • the crane 22 is controlled in the conventional manner to commence movement along the rails 34 and 35 toward the opposite end of the bay 33. Movement of the crane past the switch 37 supplies a scan start signal along the line 40 which may advantageously be connected to commence paper movement in the facsimile recorder, thus automatically initiating recording of a scan run.
  • Fur.- ther motion of the crane actuates the first pulse switch 39a, positioned in known relation to the first tank section 42 to be traversed by the scanner, and the signal provided by this and the subsequent pulse switches functions as a synchronization signal to insure that the CRT display 47 allows a complete recording sweep of the CRT screen for each section 42 of individual electrolytic cells.
  • the light areas represent the presence of heat relative to the darker (cooler) portions depicted on the thermogram.
  • the thermogram was made with the facsimile recorder 44 adjusted to provide a contrast such that the surface area of the electrolyte in the cells appears white, as exemplified at 55 on FIG. 4.
  • This preset contrast made with reference to the known or readily ascertainable temperature of the electrolyte in the cells, provides a convenient reference temperature against which other temperatures on the thermogram may be compared.
  • the horizontal dark lines on the thermogram such as the line 56, represent hanger bars which are positioned above the electrolyte to support the cathodic starter sheets.
  • the hanger bars, as represented by the dark line 56 normally are considerably cooler than the electrolyte in the cells.
  • thermal conditions corresponding to incipient short-circuits is illustrated by the following. Considering cells 12 and 13 at positions 19 and 20, respectively, white areas 57 and 58 are present where dark hanger bar lines should normally occur. An inspection of the corresponding cell positions indicated that the starter sheets connected to the hanger bars at the foregoing positions were bent, resulting in abnormal current density conditions which produced the heating of the hanger bars.
  • the faintly visible hanger bar depicted at 64 was caused by a cathode sheet having a bent corner, giving rise to a current density abnormality which produced the detected hot spot.
  • thermogram hot spots of even greater prominence than the hot spots caused by incipient vshortcircuit conditions, and so such short circuits are also detectable by the present invention.
  • the inspection personnel after reviewing the thermograms, can proceed immediately to the suspect cells and electrode positions without wasting valuable time in a routine, manual inspection of each and every cell position as previously done according to prior art techniques.
  • thermograms produced according to the present invention provide a permanent record of each cell position at various times' during the operating life of the cell, and constitute a source of data against which the work of the inspection crews and the refined copper production of the cells can be evaluated.
  • the nominal cell current density of 14 amperes per square foot was approximately one-half of the maximum current density for which the tankhouse was designed, such reduced current density being maintained for experimental purposes, and so it is reasonable to assume that the 24 hour advantage provided by the present method over conventional gauss meter techniques would correspond to a 12 hour advantage when the tankhouse is operated at full current density.
  • Method of detecting the presence of an incipient short-circuit condition of an electrode immersed in electrolytic solution comprising the step of repetitively scanning the electrode to examine the amount of infrared energy radiating from the electrode, said scanning occurring at a rate of no less than two nonoverlapping scans of at least about 0.25 inch of width per inch of electrode in 1/120 of a second.
  • an electrolytic refining operation including at least one electrolytic tank containing an electrolyte and having a plurality of spaced apart electrodes disposed in the electrolyte, the method for detecting the location of an incipient short-circuit condition resulting in an abnormal localized current flow and manifested by an "abnormal output of infrared radiation from such locaportion of the surface of said electrolytic tank; and
  • a detectable said location of an incipient short-circuit condition has adimension of at least about 1 inch in extent, and the width of each said scan path is at least about 0.25 inch.
  • Apparatus for detecting the existence of an incipient short-circuit condition in an electrolytic tank containing a plurality of spaced apart electrodes disposed in an electrolyte within the tank, with an incipient short-circuit condition being manifested by an abnormal output of infrared radiation from a location on the electrolytic tank, comprising the combination of:
  • infrared responsive means supported in elevated spaced apart relation above the electrolytic tank and operative to repetitively sweep a portion of the open electrolytic tank with a scan path having a certain width;
  • traversing means mounted above the electrolytic tank and supporting said infrared responsive means, said traversing means being operative to move said infrared responsive means over the electrolytic tank at a substantial angle to said scan path and at a predetermined rate of speed which causes a said location of previously determined minimum detectable size to be scanned by at least two successive scan paths.
  • Such electrolytic tank is one of plural such tanks arranged in a row in a tankhouse, and said traversing means is mounted in spaced relation above said row and is operative to 6 traverse said scan path across the surfaces of each of said plural electrolytic tanks in predetermined sequence.
  • Apparatus for detecting the presence of an incipient short-circuit condition in a section of electrolytic cells each of which cells contain plural electrode elements, comprising:
  • traversing means mounted in elevated relation to the section of electrolytic cells and selectively operative to traverse a certain predetermined path relative to such cells; switch means positioned to provide a control signal condition in response to the presence of said traversing means at a certain location corresponding to the beginning of said traverse path over a section of cells; sensor means carried by said traversing means and operativeto provide an output signal responsive to the amount of thermal energy which strikes a predetermined sensing area of said sensor means;
  • scanning means operatively associated with said sensor means to repetitively sweep said sensing area at a predetermined rate along a predetermined scanning path in angular relation to said path of traverse;
  • readout means connected to receive said output sig-.
  • circuit means connecting said switch means to said readout means
  • said readout means being operative to commence providing said output display in response to said control signal condition.
  • Apparatus as in claim 16 for use with a number of sections of electrolytic cells, wherein:
  • said traversing means is mounted to traverse each section of cells in said elevated relation and along said certain predetermined path;
  • said switch means is positioned to provide said control signal condition in response to said traverse means being at a certain location relative to the beginning of a first section of cells to be traversed.
  • Apparatus as in claim 16 for use with a number of sections of electrolytic cells, comprising:
  • said traversing means is mounted to traverse each section of cells in said elevated relation and along said certain predetermined path;
  • said readout means operative to provide a cell section display condition in response to each of said additional control signal condition.

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  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Electrolytic Production Of Metals (AREA)
  • Investigating Or Analyzing Materials Using Thermal Means (AREA)
US00315411A 1972-12-15 1972-12-15 Method and apparatus for detecting incipient short circuit conditions in electrolytic cells Expired - Lifetime US3809902A (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US00315411A US3809902A (en) 1972-12-15 1972-12-15 Method and apparatus for detecting incipient short circuit conditions in electrolytic cells
FI2547/73A FI62600C (fi) 1972-12-15 1973-08-14 Foerfarande och anordning foer detektering av begynnande kortslutningstillstaond i elektrolysceller
FR7337193A FR2210770B1 (tr) 1972-12-15 1973-10-18
TR18439A TR18439A (tr) 1972-12-15 1973-10-24 Elektrolitik huecrelerdeki baslangic kisa devre durumlarim ortaya cikarmaya mahsus metod ve alet
IT53379/73A IT1008587B (it) 1972-12-15 1973-10-26 Metodo ed apparato per rilevare condizioni di incipiente corto cir cuito in celle elettrolitiche
ES421439A ES421439A1 (es) 1972-12-15 1973-12-13 Procedimiento para detectar la existencia de un estado de cortocircuito incipiente en una cuba electrolitica.

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US00315411A US3809902A (en) 1972-12-15 1972-12-15 Method and apparatus for detecting incipient short circuit conditions in electrolytic cells

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US00315411A Expired - Lifetime US3809902A (en) 1972-12-15 1972-12-15 Method and apparatus for detecting incipient short circuit conditions in electrolytic cells

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ES (1) ES421439A1 (tr)
FI (1) FI62600C (tr)
FR (1) FR2210770B1 (tr)
IT (1) IT1008587B (tr)
TR (1) TR18439A (tr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003000960A1 (en) * 2001-06-25 2003-01-03 Outokumpu Oyj Method for the improvement of current efficiency in electrolysis
US20040245100A1 (en) * 2003-05-14 2004-12-09 Abouatallah Rami Michel Method, system and apparatus for testing electrochemical cells
CN104451788A (zh) * 2014-12-30 2015-03-25 合肥金星机电科技发展有限公司 电解槽极板温度监控系统
US20160146725A1 (en) * 2014-11-21 2016-05-26 Michael Bornstein Cbcs Comics System and method for signature verification
CN110760895A (zh) * 2019-11-15 2020-02-07 万宝矿产有限公司 铜电积车间极板电路故障实时监测预警方法

Citations (4)

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Publication number Priority date Publication date Assignee Title
US3209149A (en) * 1963-05-09 1965-09-28 Barnes Eng Co Infrared thermographic apparatus wherein the scanning system comprises two mirrors rotatable about orthogonal axes
US3350702A (en) * 1965-01-26 1967-10-31 Ruth A Herman Infrared detection system for fault isolation and failure prediction
US3448209A (en) * 1946-12-16 1969-06-03 Alexander Nyman Stabilized automatic mapper
US3531642A (en) * 1968-06-14 1970-09-29 Barnes Eng Co Thermographic scanner and recorder

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3448209A (en) * 1946-12-16 1969-06-03 Alexander Nyman Stabilized automatic mapper
US3209149A (en) * 1963-05-09 1965-09-28 Barnes Eng Co Infrared thermographic apparatus wherein the scanning system comprises two mirrors rotatable about orthogonal axes
US3350702A (en) * 1965-01-26 1967-10-31 Ruth A Herman Infrared detection system for fault isolation and failure prediction
US3531642A (en) * 1968-06-14 1970-09-29 Barnes Eng Co Thermographic scanner and recorder

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
Infra Red Scans For Inner Defects, by Malim Reprint from Iron Age, May 27, 1965. *

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003000960A1 (en) * 2001-06-25 2003-01-03 Outokumpu Oyj Method for the improvement of current efficiency in electrolysis
US20040232002A1 (en) * 2001-06-25 2004-11-25 Ari Rantala Method for the improvements of current efficiency in electrolysis
US7122109B2 (en) 2001-06-25 2006-10-17 Outokumpu Technology Oy Method for the improvements of current efficiency in electrolysis
CN1322170C (zh) * 2001-06-25 2007-06-20 奥托库姆普联合股份公司 增进电解中电流效率的方法
KR100840163B1 (ko) 2001-06-25 2008-06-23 오또꿈뿌 오와이제이 전기분해에 있어서의 전류효율의 개선 방법
US20040245100A1 (en) * 2003-05-14 2004-12-09 Abouatallah Rami Michel Method, system and apparatus for testing electrochemical cells
US20160146725A1 (en) * 2014-11-21 2016-05-26 Michael Bornstein Cbcs Comics System and method for signature verification
CN104451788A (zh) * 2014-12-30 2015-03-25 合肥金星机电科技发展有限公司 电解槽极板温度监控系统
CN110760895A (zh) * 2019-11-15 2020-02-07 万宝矿产有限公司 铜电积车间极板电路故障实时监测预警方法

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FI62600C (fi) 1983-01-10
ES421439A1 (es) 1976-07-01
FR2210770A1 (tr) 1974-07-12
TR18439A (tr) 1977-02-16
FR2210770B1 (tr) 1976-11-19
IT1008587B (it) 1976-11-30
FI62600B (fi) 1982-09-30

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