Copper Refining: Anode Furnace Operation

THE chief uses for copper are as a conductor of electricity and as the chief component in brasses and bronzes. For such uses, the copper must be of very high purity. H the impurities are zinc, iron, lead, arsenic, or antimony, they can be removed to a great extent by fire-refining. H, however, gold, silver, nickel, or cobalt are present, electrolytic refining is necessary. Electrolytic refining must be preceded by fire-refining and hence all impure copper must be fire-refined. The electrolytic refining of copper is most efficiently carried on when the impurities in the anodes are at a minimum. Some of the impurities tend to deposit with the copper at the cathode, while others remain in solution, decreasing the conductivity of the electrolyte and thus increasing the voltage necessary for refining. Since these dissolved impurities must be removed by continuous purifications, the amount of impurity in the anode copper should be reduced by furnace refining to some predetermined limit. Anode furnace operation aims to reduce these impurities to a minimum beyond which the cost of further furnace refining would exceed that of removing the remaining small amounts of impurities from the electrolyte. The anodes should have a fine-grain internal structure because any pieces of metal becoming detached from the anode during the electrolytic refining are inconvenient to remove from the cells and may cause short-circuits. Impurities tend to disrupt such a structure and thus form zones of weakness during corrosion. When the impurities are reduced to a satisfactory mini-mum, the anode, due to having a fine-grain structure, will corrode uniformly over the entire surface area exposed to the electrolyte. Oxides of the impurities may be volatile, in which case they pass off as flue gases, or they may form viscous slags having a lower specific gravity than molten copper, thus permitting their removal by skimming. Some impurities can be oxidized by introducing air into the bath. Due to the large solubility of oxygen in molten copper, oxygen is distributed uniformly throughout the bath and thus comes into intimate contact with all impurities. The oxides which are insoluble in molten. copper are removed either as flue gases or as slag.