Apparatus for producing metal powder by electrowinning
View Patent ↗This invention relates to an apparatus for producing a metal powder product using either conventional electrowinning or alternative anode reaction chemistries in a flow-through electrowinning cell. A new design for a flow-through electrowinning cell that employs both flow-through anodes and flow-through cathodes is described. The present invention enables the production of high quality metal powders, including copper powder, from metal-containing solutions using conventional electrowinning processes, direct electrowinning, or alternative anode reaction chemistry.
1. An apparatus for producing metal powder by electrowinning comprising:
at least two electrowinning cells wherein each said electrowinning cell comprises at least one flow-through anode and at least one flow-through cathode; and
at least one distributor plate having a plurality of injection holes configured for distribution of electrolyte, wherein said at least one distributor plate is located between the at least two electrowinning cells.
2. The apparatus of claim 1 further comprising a base portion for collecting metal powder.
3. The apparatus of claim 2 , wherein said base portion is conical.
4. The apparatus of claim 1 , wherein said at least one flow-through anode comprises at least one of titanium, tantalum, zirconium, niobium, nickel, stainless steel, a metal alloy, an intermetallic mixture, a ceramic or cermet containing one or more valve metals, or combinations thereof.
5. The apparatus of claim 1 , wherein said at least one flow-through anode comprises an electrochemically active coating.
6. The apparatus of claim 1 , wherein said coating comprises platinum, ruthenium, iridium, other Group VIII metals, Group VIII metal oxides, oxides and compounds of titanium, molybdenum, tantalum, or combinations thereof.
7. The apparatus of claim 1 , wherein said at least one flow-through cathode comprises at least one of: copper, a copper alloy, stainless steel, other specialty steel alloys, titanium, aluminum, zinc, or combinations thereof.
8. The apparatus in claim 1 , wherein said metal powder is copper powder.
9. The apparatus in claim 1 , further comprising at least one harvesting mechanism in contact with said at least one flow-through cathode to facilitate release of said metal powder from said cathode.
10. The apparatus in claim 9 , wherein said harvesting mechanism is a vibrator, an impact device, a pulse flow system, a pulsed power supply, an ultrasonic wave generator, an air bubble generator, or a combination thereof.
11. The apparatus in claim 1 , further comprising a settling tank connected to said base wherein metal powder particles are gravitationally separated from excess electrolyte solution.
12. The apparatus in claim 1 , further comprising a device installed adjacent said at least one electrowinning cell configured to collect acid mist.
13. An apparatus for producing copper powder by electrowinning comprising:
a plurality of electrowinning cells; wherein each said electrowinning cell comprises at least one flow-through anode and at least one flow-through cathode;
a distributor plate disposed between two sequential electrowinning cells in said plurality of electrowinning cells wherein said distributor plate comprises a plurality of injection holes configured for distribution of electrolyte between said two electrowinning cell;
at least one harvesting mechanism to facilitate release of said copper powder from said at least one flow-through cathode; and
at least one base portion for collecting copper powder.
14. The apparatus of claim 13 , further comprising a settling tank connected to said base wherein copper powder particles are gravitationally separated from excess electrolyte solution.
15. The apparatus of claim 14 , wherein said at least one flow-through cathode comprises a plurality of rods.
16. The apparatus of claim 14 , wherein said at least one flow-through cathode comprises at least one of: copper, copper alloy, stainless steel, titanium, aluminum, zinc, or combinations thereof.
17. The apparatus of claim 14 , wherein said at least one flow-through cathode is electropolished or chemically passivated stainless steel.
18. The apparatus of claim 14 , further comprising a device installed adjacent said at least one electrowinning cell configured to process acid mist.
19. The apparatus of claim 14 , wherein said harvesting mechanism is a vibrator, an impact device, a pulse flow system, a pulsed power supply, an ultrasonic wave generator, an air bubble generator, or a combination thereof.