The Effect of Brush Plate Structure and Operating Parameters on the Energy Consumption of Electrolytic Cells

Abstract

The nickel powder brush plate is a core component of the direct contact between the cleaning machine and cathode plate of an electrolyzer, and its movement in the electrolytic cell will affect the energy consumption of the electrolyzer. In order to optimize the structure of the brush plate, a cleaning trolley brush plate was taken as the research object, a mathematical model of its electrolyzer was established, and the reliability was subsequently verified. The influence of the structural and operating parameters of the brush plate on the energy consumption of the electrolytic cell was studied. The research results show that additional energy consumption is the lowest in the process of cleaning a return grooved brush plate. Brush plates with a large slotting area have less impact on the energy consumption of the electrolyzer. The slotting method, where the anodes are arranged directly opposite each other and relatively concentrated, can be adapted to render a more uniform current density distribution on the anode surface, with lower energy consumption and less variation in voltage and current. With the increasing number of slots from one to three, the current density distribution on the anode surface became more uniform, with a reduction in the variation range of the slot voltage and current in the branch where the cathode plate was cleaned and a decreased energy consumption. With the linear increase in brush cleaning speed, the impact time of the brush plate on the electrolyzer decreased nonlinearly, and as the extent of this decrease gradually diminished, the additional energy consumption showed the same trend. These research results were then used as a basis for optimizing the existing commonly used empirical C-brush plates. Following optimization, the current density distribution on the anode surface was found to be more uniform, the variation amplitude of tank voltage was reduced by 34%, the current drop amplitude of the branch circuit where the brushed cathode plate was located was reduced by 39%, the impact time on the current field of the electrolytic tank was reduced by 40%, and the additional energy consumption was reduced by 50.9%. These results can be served as a reference for further theoretical research related to brush plates.