Identification of optimum conditions for zinc electrowinning in high-purity synthetic electrolytes

Abstract

The optimum conditions for zinc electrowinning in synthetic acidic zinc sulphate electrolytes (0.8 M ZnSO4+1.07 M H2SO4) were determined using response surface statistical analysis. The coulombic efficiency (QE) was optimized with respect to temperature (T), current density (J) and electrode rotation rate (n). For an electrolyte prepared from AR zinc sulphate and Aristar sulphuric acid, containing trace lead and nickel, QE reached a maximum of 98.8% on a zinc substrate under the following conditions:T=50°C,J=500 A m−2,n=35s−1. For a very-high-purity electrolyte, prepared by dissolution of 99.9999% zinc in Aristar sulphuric acid, a maximum QE of 98.4% was predicted and obtained at:T≃61°C,J≃890 A m−2,n≃38s−1. Using a statistical response surface model calculated during the optimization process, QE contours giving an overall view of electrolyte performance were constructed. The QE responses were determined principally byT andJ, with significant interaction betweenn andJ orT andJ, depending on the impurity composition of the electrolyte. The model was also used to predict the QE response of the above electrolytes under conditions similar to industrial practice.