Aluminum Cathode Plates for Zinc Electrowinning
Engineered for high-yield zinc electrowinning, our various specifications of Aluminum Cathode Plates combine robust construction with innovative features to maximize productivity and minimize lifetime costs. With a proven capacity for mass-producing 3.6 m² cathode zinc, these cathode plates are built for durability, featuring advanced welding techniques, comprehensive anti-corrosion coatings, integrally molded edge strips, and the V-groove design at bottom of the aluminum blade for effortless stripping cathode zinc. This results in a superior solution that delivers enhanced efficiency and reliability for modern zinc electrowinning plants.
Introduction to Aluminum Cathode Plate
Provide aluminum cathode plate with longer service life. Meets client requirements for various specifications
Details of Anode Plate and On-site Photos
Data of Performance
| Materials of the Blade | Aluminum (1070H18AL) |
| Materials of the Conductive Beam | Aluminum (6101AL) for Conductive Beam and Lifting Lugs; ASTM C11000 Copper for Conductive Block |
| Effective Plate Area | 2 ~3.6 Square Meters |
| Application for | Zinc EW |
| Service Life under Normal Conditions | 18 Months for Sulfuric Acid Process; 6~8 Months for Ammonia Process |
1. The hanger bar is made from a whole-body aluminum rod.
2. The aluminum blade is made from aluminum alloy 1070, Al ≥ 99.7%, HBS: 32-35.
3. The copper conductive block is friction-stir welded to hanger bar or fixed by bolts.
4. The portion of the aluminum cathode plate above the liquid level line (excluding the copper conductive block) is coated with an anti-corrosion material. This anti-corrosion material is typically a solvent-free epoxy resin coating or a patented vulcanized rubber.
5. The surface finish grade of the aluminum blade is 2B grade.
6. Friction stir welding is used for welding the aluminum blade and the conductive beam.
Engineered for Scale and Efficiency: Multi-Specifications Aluminum Cathodes for Modern Zinc Production
Maximizing productivity in zinc electrowinning requires cathodes that are not only durable but also optimized for high-yield operations. Our large-format Aluminum Cathode Plates are designed specifically for this purpose. With a proven ability to mass-produce substantial 3.6 m² (1.8 m² per side) units, we provide the robust infrastructure needed to enhance your plant’s output. Every detail, from the advanced welding techniques to the innovative protective coatings, is engineered to reduce operating costs, extend service life, and streamline the stripping process.
Precision Engineering for Demanding Applications
Our manufacturing process integrates robust materials with advanced techniques to create a cathode built for performance and longevity.
1. High-Strength Aluminum Blade and Conductive Beam:
We utilize high-purity, corrosion-resistant aluminum alloy, sourced from reputable suppliers like CHINALCO, to form the conductive beam and cathode blade. This ensures a perfect balance of conductivity, light weight, and structural integrity.
2. Advanced Welding for Superior Connection:
For small and medium-sized plates, we use automated Friction Stir Welding (FSW). This solid-state process creates a stronger, more reliable joint than traditional fusion welding, with minimal distortion and no porosity. For our large-format 3.6 m² cathode plates, we use specialized manual acetylene welding techniques, ensuring a deep, robust penetration capable of withstanding the stresses of automated handling.
Friction Stir Welding between the Medium Sized Blade and the Conductive Beam
Cross-sectional Details of the Friction Stir Welding
Manual Acetylene Welding between the Large Sized Blade and the Conductive Beam
3. Comprehensive Anti-Corrosion Protection:
To significantly extend the cathode’s life, we apply a specialized protective coating to the entire aluminum cathode plate surface above the liquid level and on the edge strips. This coating acts as a barrier against corrosive acid mist, a primary cause of degradation.
- Solvent-free epoxy resin coatings
- Patented vulcanized rubber
4. Durably Molded PP Edge Strips:
The edge strips are not simply attached; they are injection-molded from high-grade PP plastic directly onto the aluminum blade using custom molds. This creates a permanent, tight-fitting seal that withstands physical impact and chemical exposure far better than adhered strips, dramatically extending the life of both the strip and the blade.
5. V-Groove at the Bottom of the Blade for Easy Stripping:
The bottom edge of the aluminum blade is precision-milled with a continuous V-Groove. This design creates a natural fracture point, guiding the zinc sheet to break away cleanly and consistently during the automated stripping process, reducing damage and improving efficiency.
Key Advantages for Your Zinc Plant Operation
1. Proven Large-Scale Production Capability:
Our ability to reliably manufacture 3.6 m² aluminum cathodes makes us an ideal partner for greenfield projects and large-scale plant expansions, ensuring a steady supply of high-quality components.
2. Unmatched Welding Integrity:
The use of Friction Stir Welding for smaller plates provides a joint strength superior to traditional methods, while our specialized manual techniques guarantee durability for the largest plates.
3. Maximum Service Life:
The combination of a anti-corrosion coating on the both sides of the edge strips areas and above the liquid level line and our integrally molded PP edge strips provides a multi-layered defense against the primary causes of cathode failure, offering the lowest total cost of ownership.
4. Maximum Service Life:
The precision-milled V-Groove at the blade’s bottom ensures a clean separation of the zinc sheet, reducing stripping time and minimizing the risk of blade damage.
Technical Specifications:
Blade and Conductive Beam Material: High-Purity Aluminum Alloy Standard Size: 2 ~ 3.6 m² (customizable sizes) Edge Strips: Injection-Molded PP Plastic Welding: Automated Friction Stir Welding (small/medium plates) or Manual Acetylene (large plates) Special Features: Anti-corrosive coating on the both edge strips areas and above liquid level line, bottom V-Groove for stripping.
More Than Just a Supplier of Anode and Cathode Plates
PRS has a rich experienced engineering and technique team. We can provide EPC services including full process consulting, solution optimization, equipment integration / supply in system and on-site commissioning or remote guiding.
Process Consulting
Our seasoned sales and engineers teams will communicate with you. We are just consultant of your whole EW process, according to your requirements and local conditions.
Drawings Optimization
The senior engineers from PRS can discuss the drawings with you, and provide reasonable suggests to optimize your drawings in maximum according to their rich experience.
System Supply
PRS is able to supply system equipment to you with a full range of crushing – ball milling – flotation – leaching – extraction – electrowinning, including certificates required.
On-site Commissioning
On-site commissioning, guidance and installation are available if in need, and remote guidance service by engineers or technique experts from PRS is also open for you.
Upgrade to Aluminum Cathodes Designed for Higher Yields.
Move beyond the limitations of standard cathodes. Partner with us to implement a solution that boosts your productivity, reduces maintenance costs, and is built to last.
