Cairo University Metallurgical Department

Faculty of Engineering 3rd Year Metallurgy

Department of Mining, Petroleum Theory of Metallurgical Processes
and Metallurgical Engineering 2011/2012 (2nd Term)

Sheet 4: Electrometallurgy

QUESTION NO. 1
Calculate the thickness of the chromium plating
deposited in 2.5 min at a current density of 0.2 amp/cm2
and current efficiency of 14%.

(Atomic weight of Cr =52 g/mole, Cr valence in a solution

of CrO3=6, and density of Cr = 7.1g/cm2).

Solution
Area=1 cm 2

I = 0.2 Amp

96500 ………………… equivalent w.t. of (Cr)

96500 ………………… m.wt./valence= 52/6gm

0.2 * 2.5 * 60 ………………… X

Page 1 of 49
Theoritical wt. of (Cr) deposited / cm2

= (0.2*2.5 * 60 * 52)/(96500 * 6) = 2.694 * 10-3 gm

Current Efficiency = Actual wt./ theoretical wt.

Actual wt. = (14 * 2.694 * 10-3 ) / (3.7716 * 10-4)

Density = wt. / Volume = (wt. / Area * Thickness)

Thickness = wt. / (Area * Density) = (3.7716 * 10 -4) / (1 * 7.1 )

( Thickness = (5.31 * 10-5) cm )

Page 2 of 49
 QUESTION NO. 2
In a plant for extraction copper from CuSO 4 by
electrolysis, the average resistively of the solution is 5
Ω.cm; electrodes 4 cm apart; gas voltage at the anode, 0.5
V; current density, 165 amp/m2; voltage drop, cathode
plate to busbar, 0.05 V, anode plate to busbar, 0.1 V.
current efficiency of the deposition, 85%. Current per
tank, 1000 amp.
H2 + 0.5 S2 + 2O2  H2SO4 ΔH°= 212,400 Cal.

H2 + O  H2O ΔH°= 68,380 Cal.

Atomic weight of Cu=63.6 gm/mole.

Required:

A. The voltage absorbed to overcoming the ohmic

resistance of the electrolyte.
B. The voltage absorbed in chemical reaction, on the
assumption of Thomson's rule.
C. The voltage drop, anode to cathode.
D. The voltage drop, busbar to busbar.
E. The weight of copper deposited per day per tank.
F. The power in kilowatts per tank. The energy used in
kilowatts-hours per kilogram of copper deposited.

Page 3 of 49
 Solution
Resistivity = 5 Ω.cm L = 4 cm
EG = 0.5 v Current Density = 165 amp/m2
Activation polarization → Active surface
E : Cathode Busbar = 0.05 v E : Anode Busbar = 0.1 v
Current Efficiency = 85% I : Tank = 1000 Amp
Assume A = 1 m2 = 104 cm²

A - Eс = I * R
= I * r * L\A
= 165 * 5 * 4\104
= 0.33 v

B - H2 + 0.5 S2 + 2O2  H2SO4 ΔH°= 212,400 Cal. (+)

Cu + 0.5 S2 + 2O2 CuSO4 ΔH°= 200,640 Cal. (-)

H2 + O  H2O ΔH°= 68,380 Cal. (-)

CuSO4 + H2 Cu + H2SO4 + 0.5 O2 ΔH°R= -56620 Cal.

ΔH°R = -56620 = -ZF∆E

∆E = (55620*4.18)\(2*96500) = 1.2263 volt

Page 4 of 49
C - E cell = Eс + E R.P +E.G = 0.33 + 1.22 + 0.5 = 2.054 volt

D - E total (busbar to busbar) = 2.054 + 0.05 +0.1 = 2.2 volt

E - 96500  63.6\2
24*3600*1000 X

Then.Theoretical wt. of Cu \day\tank = 28471.7 gm

actual Wt. = .85*28471.7 = 24.2 Kg

F - Power = I tank * V tank

Inside tank V tank = V cell
I tank = ∑ I cell
With tanks V tank = ∑ V cell
I tank = I cell
Power = 1000 * 2.2 = 2200 watt

G - Energy = 2200 * 24\1000 = 52.8 Kw.hr

Page 5 of 49
 QUESTION NO. 3
A copper refinery using a series system that has 400
tanks, each containing 40 anodes 61 by 91.5 cm. the current
density is 0.017 amp/cm2. The anodes are 1.43cm thick at the
start and are spaced at 5.1 cm center to center. The
electrolyte has a resistivity of 1.55 Ω.cm. The current
efficiency is 72%.
Required:
A. The copper output of the plant per day.
B. The voltage used in overcoming the resistance of
the electrolyte per tank.

Solution
400 tank (40 anode + 1 = 41 cathode)
A= 2*61*91.5 = 11163 cm3
C.D.=0.017amp./cm2 L=5.1/2-2(1.43/2)=1.85cm r=1.55
Ω.cm
96500  63.6/2
0.017*11163*24*3600  ?
Th. Wt. of copper output per day= 5403.1 gm
Actual wt. of copper output per day= 0.72*5403.1=3890.23
gm
wt. of copper/tank = 3890.23*41 = 159499.5 gm / tank / day

Page 6 of 49
wt. of copper/plant = 159.5 * 400 = 63799.77 kg = 63.8 ton /
day
Ec = I * R = I * r * L/s = 0.017*11163*1.5*1.85/(61*91.5) =
0.0975 volt.

Page 7 of 49
 QUESTION NO. 4
The copper electrolytic refinery plant has a capacity of
217,440 ton of copper annually (365days), figured at a
current density of 0.0186 amp/cm2 of cathode surface. Each
tank has 30 cathodes and 29 anodes, multiple systems. The
cathodes measure 77 by 98 cm and are entirely immersed
in the electrolyte. The average distance from anode to
cathode surface is 3.43 cm the voltage per tank is 0.24V.
The tanks are connected in four separate circuits, with one
generator to each circuit.
Required:
A. The number of tanks if all were in regular
operation, with 93% current efficiency.
B. The voltage and current of each generator.
C. The resistivity of the electrolyte, assuming 50% of
the voltage drop used in overcoming electrolyte
resistance.

Solution
Inside the tank:
I = variable in series V = const. in parallel
Between tanks (in the plant):
I = const. V = variable

Page 8 of 49
96500  63.6/2
0.0186*2*77*98*24*3600  ?
Th. Wt. of copper output per day = 7992.3 gm.
Actual wt. of copper output per day (per cathod) =
0.93*7992.3
= 7432.56 gm.
Actual wt. of copper output per year (per cathod) =
365*7432.56
=2.713 ton.
Actual wt. of copper output per tank = 30(no. of
cathode)*2.713
= 81.389 ton/year.
Total copper (given) = 217,440 ton/year
N(no. of tank) =217,440/81.389 = 2671.6 tank = 2672 tank.
Area of cathode = 2*77*98 = 15092 cm2
Icathode =C.D. * Area = 0.0186*15092 = 280.7 amp.
Itank = 280.7 * 30(no. of cathode) = 8421.336 amp.
Ec = ?
Vtank = 0.24 volt
Ec = 50/100 *0.24 = 0.12volt
R = Ec / I = 0.12/280.7 = 4.275 * 10-4 Ω
R = r * (L/S) L= 3.43 cm S= 77*98 = 7546 cm2
r= 0.9 Ω.cm

Page 9 of 49
In one circuit = N/4 = 2672/4 = 668 tank/circuit
Volt for each generator (in series) = 668*0.24 = 160.32 volt
Vtank = 160.32volt Itank = 8421.336 amp
Total power = Vall tanks *Itank = 2672*0.24*8421.33 = 5400.43
KW.

Page 10 of 49
 QUESTION NO. 5
A copper electrodeposition plant contained in the
section Lead- Antimony anodes 572 tanks, each tank
having 61 anodes and 62 cathodes. The size of the cathodes
was 92 by 122 cm and the current density 0.014 amp/cm2.
The current efficiency of deposition was 86%. The oxygen
gas voltage was 0.42 V. Assuming 0.35 V for conduction,
contacts, etc.

Required:
A. The voltage per tank
B. the copper deposited in the plant ton per year
C. The energy cost per Kg of copper deposited in
year assuming the cost of power is $150 per
Kilowatt-year.

Solution
CuSO4 + H2SO4 Cu + H2SO4 +O ΔH = -56,620 cal
ERP = -ΔH/23060n =56620/23060*2 =1.2277 =1.23 Volt
Etot =1.23 + 0.35 +0.42 = 2 Volt
96500  63.6/2
0.86*0.014*2*92*122*365*24*60*60  ?
Cu deposited / cathode = 2808733.63 gm/year =2.8087
ton/year
Page 11 of 49
Cu deposited / all cathode = 62*2808733.63
= 174141485gm/year
Cu deposited in the plant =174141485*572= 9960.89
ton/year
Current / tank = 0.014*2*92*122*62 = 19485 amp/tank
Power = I * V = 572*19485*2 = 22.29 K Wt
Power cost = 22.29*150 = 3343.6 $/ Kilowatt-year
The energy cost per Kg of copper deposited in year =
(24*3343.6)/(9960*103) =0.8056$

Page 12 of 49
 QUESTION NO. 6
A plating work uses a high pH nickel sulfate bath,
saturated with boric acid; the latter constituent is not
decomposed in electrolysis. Platings are made with a cathode
current density of 0.026 amp/cm2 for 45 min. the current
efficiency of nickel deposition is 95% and of nickel corrosion
at the anode 90%. (Assume that 5 % of the current librates
H2 at the cathode, while 10 % librates O2 at the anode.)
The density of nickel=8.91 gm/cm3, the atomic weight of
nickel= 58.7 gm/mole
Required:
A. The thickness of the nickel plating, in millimeters.
B. The volumes of O2 and of H2 liberated in 45 min, in
cubic centimeters.

Solution
Assume area=1 cm2
I=0.026 amp
96500→58.7/2
0.95*0.026*45*60→?
Then weight decomposed of Ni =0.0203 gram
Volume =wt/density =area * thickness

Page 13 of 49
Then thickness = 2.276*10-3
Wt of H2 =0.05/100 )*0.0203 =1.015*10 -5 gram
Volume of H2 =?
2gram →22.4 m3
1.015*10-5→?
Then volume =113.68 cm3
Wt of Ni deposited =wt of Ni corroded
Wt of Ni corroded =0.0203 gm
Wt of O2 =(10/100)*0.0203=2.03*10-3 gm
Then to get volume same as H2 =
(2.03*10-3)*22.4/2*16 =1421 cm3

Page 14 of 49
 QUESTION NO. 7
An electrolytic zinc plant is to be designed to turn out 100
ton of zinc per day. From laboratory experiments, an
average current efficiency of 85% can be expected. Assume
that 15 % of the current decomposes water into hydrogen
and oxygen. Cathodes receive deposit on both sides;
immersed surface of each, 0.9 m2; current density,
300amp/m2; working voltage, 3.5 V per tank. Each tank
contains 20 cathodes and 19 anodes.
The atomic weight of the zinc =65.4 g/mole, the
density of the zinc =7.13 g/cm3
Required:
A. The necessary number of tanks in continuous
operation.
B. The net electric power required in the whole plant.
C. The thickness of the deposit stripped from the
cathode, assuming it stripped every 24 hr.

Solution
9650065.4/2
(0.85*300*0.9*2)*(24*60*60)  X
X=13.4 kg
100*1000N

Page 15 of 49
(20*13.4) kg1
Number of tanks =373 tanks
Power=I*V = (300*0.9*2*20)*(3.5*373) =14.1 kW
Density of zinc =7.13 g/cm3
Volume = wt. /density =A*t
Actual wt. =13356 gram
Thickness = 13356/7.13*0.9*10000 =0.208 cm

Page 16 of 49
 QUESTION NO. 8
At the electrolytic zinc plant, there are three circuits of 150
tanks each. Each circuit has two motors set connected in
parallel; each set delivering 4,000 amp at 500 V. the current
density is 0.11 amp/ cm2. The immersed area of each cathode is
68.5 by 55.5 cm. the starting cathodes are of aluminum; they
are removed and stripped at intervals of 8 to12 hr. The
distance from anode to cathode surface is 1.6 cm. assume that
20% of the average tank voltage is used in overcoming the
resistance of the electrolyte. The average current efficiency is
90.5%.

Required:
A. The number of cathodes per tank.
B. The capacity of the plant in ton/year
C. The energy used, in kilowatt-hours per Kg of zinc.
D. The maximum and the minimum thickness of zinc stripped
from the cathode plates in centimeters.
E. The average resistivity of the electrolyte in Ω.cm.

Solution

Page 17 of 49
3 CIRCUITS
NO. OF TANKS =3X150=450 TANKS
EACH TANK →2 MOTOR GENERATOR
I =4000 AMP V =500 V

C.D =0.11 AMP / CM2

AREA = 2X68.5 X55.5=7603.5 CM2

I = C.DXAREA
I =0.11 X 7603.5 = 836.385 AMP / CATHODE
TOTAL I = 8000

NO. OF CATHODES =8000/836.385 =10 CATHODES

TIME→ 8 TO 12 HRS =

96500→ 65.6/2
0.905X 836.385 X365 X 24 X60 X 60→ ?
WT. OF ZINC DEPOSITED / CATHODE = 8,113.5 KG / YEAR
WT. DEPOSITED / TANK = 81,135 KG / YEAR

WT. OF ZN DEPOSITED / PLANT = CAPACITY

= 81.135 X 450 = 3,651,0750 GM / YEAR = 3,651 T/ YEAR

E = 500/150 =3.33 V
E CATHODE = 20/100 X3.33 = 0.66 V .

18
E CATHODE = I X R
R = E/I = O.667/ 836.385 = 0.000797 Ω
R = R L/ S
R = R X S/L = 0.000797 X 55.5 X 68.5 / 1.6 = 1.894 Ω.CM
POWER = I X V =8000 X 500X 3 = 12X10⁶ W
ENERGY CONSUMED = 12,000 X 24 =288,000 KW-HR
ENERGY CONSUMED / KG OF ZN DEP . = 288 X 10⁶ / 3,651 X 10⁶
= 0.078 KW-HR/ KG OF ZN DEP.
96500 → 65.6
(8X 60 X 60 ) (0.905X 836.385) → ? MIN
(12 X60 X 60 ) (0.905 X 836.385) → ? MAX
WT. MIN = 7409.6 GM
WT. MAX = 11114.4 GM
V MIN = A X TH MIN TH MIN =7409.6 / 7.13 X 68.5 X 55.5
=0.273 CM
V MAX = A X TH MAX TH MAX = 11114.4 /7.13 X 68.5 X55.5

=0.41 CM

19
 QUESTION NO. 9
Gold bullion has a composition of 91% Au, 6%Ag, 2%Cu, and
1%Pb. It is refined in an electrolyte of AuCl3 plus HCl. The
Tank receives 100 amp; efficiency of the deposition,
100%. The anodes corrode uniformly.
Atomic weight of Au=197.2 g/ mole, Ag= 107.9 g/mole,
Pb=207.2g/mole

Au + 1.5 Cl2 AuCl3 ΔHᴼ= - 32750 Cal

Ag + 0.5 Cl2AgCl ΔHᴼ= - 30600 Cal.

Cu + 0.5 Cl2CuCl ΔHᴼ= - 34300 Cal.

Pb + Cl2 PbCl2 ΔHᴼ= - 79120 Cal.

Required:
A. The weight of the gold deposited, per day.
B. The weight of the anode corroded, per day
C. The gold in the anode slim.
D. The voltage for the gold deposition.
E. The total reaction voltage.
F. The voltage drop due to the anode composition.

Solution

20
96500→197.2
100*24*60*60 → X
X= wt. of Au deposited /day =5885 gram
Total weight of the anode corroded /day =5885/0.91 =6467.4
gram
No of coulombs needed for dissolve 1 gram of the anode
uniformly
Therefore: Au=0.91 gram, Ag=0.06 gram, Cu =0.02 gram,
Pb=0.01 gram
96500→197.2/3
X→0.91
X=for Au=0.91 (96500/(197.2/3))=1336 coulomb
Same for Ag, Cu, Pb: Pb=9 coulomb
Ag=53.7 coulomb
Cu=30 coulomb
Total =1429 coulomb
Total coulomb needed for dissolve 1 gm from the anode -1429
amp sec
100*24*60*60 →X
1429→1 gm.
Then X= wt. of the anode corroded /day = (100 *24*3600)/1429
= 6046 gm.
21
Wt. of Au corroded from the anode =0.91 *60.46=55.02 gram
No of Au that will be reduced due to the use of the anode 5885-
5502=383 gram of Au depletion.
Au +3/2 Cl2 →AuCl3 ∆H=-32750 Cal
E≈-∆H /23060n=32750/23060*3=0.473 volt
Which is the cathode voltage as pure Au is deposited but at the
anode only 1336/1429=0.935 of the current used.
E=0.935*0.473=0.442 volt
Voltage generated at the anode:
Voltage of AuCl2 = (1336/1429)*0.473=0.443 volt
Voltage of AgCl= (53.7/1429)*(30600/23060*1) =0.05 volt
Voltage of CuCl= (30/429)*(34300/23060*1)=0.031 volt
Voltage of PbCl2= (9/1429*79120/23060*2)=0.011volt
Total voltage at the anode =0.534 volt
Voltage drop =voltage of cathode deposited for pure Au -
voltage of uniform corroded for the given composition =0.4473-
0.534=-0.061 volt
Or 0.061 volt is generated.

22
 QUESTION NO. 10
Gold bullion refined contained 89% Au, 8%Ag, 2%Cu, and
1%Pb. Au goes to AuCl3, Ag to AgCl, Cu to CuCl, Pb to PbCl2.
the gold is deposited pure at 100% efficiency. The anodes
corrode uniformly, and no chlorine is set free. The current
passing is 500 amp.
Required:

A. The weight of the gold deposited per day.

B. The weight of the anode consumed per day
C. The depletion of the electrolyte in gold.
D. The reaction voltage of the cell as based on the assumption
of Thomson's rule.

Solution

Au = 0.89 *( ) = 1305

Ag = 0.08 * ( ) = 72

Cu = 0.02 * ( ) = 30

Pb = 0.01 * ( )=9

Total = 1416 coulombs (amp .sec)

23
The wt. of teanode =

= = 30510 Grams

Grames of anode corroded = 30.51

Au dissolved = 0.89 * 30515 = 27150 gm

Depletion of Au = 29420 - 27150 = 2270 gm

( Au , Cl3 ) at equilibrium

Au + C l3 → Au Cl3 Δ H = -32750 cal

E rp = = = 0. 473 volt

C .E. of au = = 92.2

E rp = 0.922* 0.436 volt

Anodic voltage

( Au Cl3) = (1305/ 1416) *

= 0.436 volt

( Ag Cl) = ( )* ( )

= 0.067 volt
24
(Cu Cl ) = ( )*( )

= 0.032 volt

( Pb Cl2) = ( ) *( )

= 0.011 volt

TOTAL = 0.546 volt

E.rp =Ec - Ea

= 0.473 – 0.546 = -0.11 = + 0.11

25
 QUESTION NO. 11
An aluminum plant has five series of cells with 60 cells in each series
takes 28,000 amp and 450 volts. The current efficiency is 88%.

Atomic weight of Al=27 g/mole.

C + 0.5 O2 CO ΔGᴼ= - 26,700-20.95 T Cal/mole.

C + O2 CO2 ΔGᴼ= - 94,200 - 0.2 T Cal/mole.

2 Al(L) + 1.5 O2 Al2O3 ΔGᴼ= - 400,700+76.7 T Cal/mole.

Required:
A. The annual capacity of the plant.
B. The energy consumed in kilowatt-hour per Kg of metal produced.
C. The voltage absorbed by the chemical reaction, assuming that
one- third of the oxygen from Al2O3 goes to CO, two- third to
CO2.
D. The rate of the heat production in the cell, in calories per minute.
E. The total volume of gases librated in each cell in 24hr.

Solution
96500→27/3
0.88*28000*24*60*60 →X
X= wt. of Al deposited in 1 day for 1 cell = 198.5 Kg
The production of the cell /year =198.5 *365=72.5 ton/year

26
Production of the factory 1 year = production of the cell *no of
cells =72.5 *300 =217750 ton/year
Power = I*V V= 450/60= 7.5 volt for each cell
Power for each cell =210KW
Energy cost of each cell /day =210*24=5040 Kw-hr
Energy cost of each cell /Kg of AL produced=5040/198.5 =25.38
Energy cost per day /Kg of Al produced per day=25.38Kw –hr.
/Kg of Al
Al2O3 +2C →2Al+CO2+CO
∆G Al2O3=-400700+76.7T
∆G CO2 =-94200-0.2T
∆G CO = -26700-20.95T
T=950+273=1223k
∆G=-ZFEEquation 1+2-3
Then: Al2O3 + 2C →2Al +CO +CO2 →∆G1+∆G2-∆G3=-
160251.2 Cal
∆G=-ZFE
Therefore: total volt =ET =-160251.2 /23060*2*3 = -1.15821 Volt
Then to get the heat:
160251→2*27
X→ 198549.9/24*60

27
Therefore: heat =409.175 kcal/min
Then to get volume: PV=NRT
P=1ATM, V=22.4 litre, R=0.082 atm lit/k0, T=273 k
Each 54 gram AL produces 2 mole of gases and each mole
occupies 22.4 litre
Therefore: 54 grams AL are associated with 44.8 Litre
54→44.8
198550→X
Therefore volume= 164.7*1000 litre =164.7 m3

28
 QUESTION NO. (12)
An aluminum plant runs six series of cells with 70 cells in
each series. Each series takes 20,000 amp and 500 volts. Each
cell produces 135.9 Kg of metal per day. The inside dimensions
of the carbon lining of the bath are 2.4 by 1.2 by 0.3 m.

Required:

A. The current density at the cathode, assuming the sides of the

cell inactive.
B. The annual capacity of the plant.
C. The current efficiency
D. The energy required in kilowatt-hours per Kg of metal
made.

Solution
96500 → 27/3
20000*24*60*60 → X
Wt. of AL deposited of cell \ day = 16116.06 gm
Actual wt. = Efficiency * Theoretical
Efficiency = 135.9 \ 161.6 = 84.3 %
E ( each cell ) = 500 \ 70 = 7.14 volt
29
Power = I * V = 20000 * 7.14 = 142.82 Kw
Energy consumed = 142.82 * 24 = 3428.5 Kw.hr

Energy consumed \ kg produced in day =

3428.5 \ 135.9 = 25.23 Kw-hr\kg of AL produced in day
C.D = I \ A = 20000 \ 2.4 * 1.2 * 2 = 3472.22 amp\ cm²
Annual capacity of the plant = 135 * 70 * 6 * 365
= 20833.470 kg \ year
= 20.8 t\year

30
 QUESTION NO. (13)
The output of an aluminum plant is 35,000 Kg/day. It uses
37,500 Kw, the individual cells taking 7 volts and the current
passing through each being 15,000 amp. Assume that the
reduction of the alumina is according to the equation:
2Al2O3 + 5C 4CO + CO2 + 4Al.

The aluminum is tapped from the cells at 950°C.

Required:
A. The number of the cells operating.
B. The current efficiency of the producing the aluminum.

Solution
T = 950 + 273 = 1223 K

4AL +3O2  2AL2 O3 ΔG1 =

C +O2  CO2 ΔG2 =

4C + 2O2  4CO ΔG3 =

THE TOTAL REACTION

31
 2AL2O3 + 5C  4AL (L) +CO2 + 4CO

ΔGT = ΔG2 + ΔG3 - ΔG1

ΔGT = -2 * -307018.2 - 94446+ 4* -52321

ΔGT = 310307.4 CAL / MOLE
POWER = I * V = 37500 * 0.001
37500 * 0.001 = 15000 *V
V = 2500 VOLT
N CELLS = ( VTOTAL / V CELL)
= 2500/ 7 = 357 CELLS
96500 ( 27/ 3) = 9
1500 * 24 * 60 * 60  X
WT OF AL DIPOSITED / DAY = 43168 KG / DAY
OUT PUT PER DAY = 3500 KG
THE CURRENT EFFICINCY η = ( ACTUAL/
THEORITICAL)
= (3500 / 43168 ) = 81

32
 QUESTION NO. (14)
In the Hall-Haroult bath, Al2O3 is dissolved and practically
takes the liquid from at 1000°C. It is electrolyzed at 1000°C to
Al and a mixture of 50% CO and 50 % CO2. Each cell takes
15,000 ampat 6.5 volt. The lower surface is melted Al, the area
150 by 250 cm. the anodes work at an average distance of 3 cm
from the cathode surface. The plant uses 40,000 Kw.
Required:
A. The output of the plant per day taking the current
efficiency at 80%.
B. The reaction voltage that will be required in the ordinary
running of the cell.
The resistivity of the electrolyte. (Allow 0.6 volt for gas voltage
and contacts. Assume that the voltage cross-sectional area for
current flow is 10% less tha

C. n the area of the cathode surface.

Solution
The planet(all tanks) power = 40,000*10 3 W = I*V*N(no. of
tanks)
=15000*6.5*N N= 411 tank.

33
 96500  27/3
0.8(ζ)*15000*24*3600  ?
Actual wt. of Al produced/day (for 1 tank) = 96696.4 gm.
For all tanks = 411*96696.4 = 39.742 ton/day
Al2O3 + 2C 2Al(L) + CO + CO2 at T= 1273K
(-) 2Al(L) + 3/4O2 Al2O3 ΔG1 = -303,060.9 cal/mole
(+) C + 1/2 O2 CO ΔG2 = -53,369.4 cal/mole
(+) C + O2  CO2 ΔG3 = -94,454.6 cal/mole
ΔGT = +303,060.9 - 53,369.4 - 94,454.6 = 155236.9 cal/mole
N = 2*3 = 6
E = - ΔGT / Z F = -155236.9/(6*23060) = -1.122 volt
EG =0.6 volt (given)
Etot = Ec + ERP +EG
Ec =I * R = I * r * L/S
L= 3 cm, S = 15*250*0.9 = 337
Etot = 6.5 volt (given) = Ec -1.122 +0.6
Ec = 6.5-0.6+1.122 = 7.022 volt
r = (Ec*S)/(I*L)
= (7.022*15*250*0.9)/(15000*3) = 0.526 Ω.cm

34
 QUESTION NO. 15
An aluminum plant has 800 cells, each is taking 20,000 amp at
6.8 volt. The output of the plant is 108.7 ton of aluminum per
day. The gases escaping from the pot analyze 40% CO and
60% CO2. The reduction takes place at 1000°C; the Al 2O3
dissolved in cryolite is practically in the liquid state at this
temperature.
Required:
A. The current efficiency of the deposition.
B. The chemical reaction expressing the reduction of the
Al2O3 and the consumption of the electrodes.
(Al2O3 + 3C  3.2 Al(L) + 1.2 CO + 1.8 CO2)
C. The voltage of the reaction as calculated according to
Thomson’s rule from the reaction beginning and ending
at 1000 °C.

Solution

1.2 C + O2 → 1.2 CO

1.8C + 1.8 O2 → 1.8 CO2

3.2 AL + (1.6 * ) O2 → 1.6 AL2 O3

35
TOTAL REACTION

1.6 Al2 o3 + 3c → 3.2 AL + 1.2 CO + 1.8

96500 → (27/3)
(20000 * 800) * ( 24 *60 *60 ) → X ( Wt of Al )

Wtof Al = 128928.5 kg / day

Output ( actual ) = 108720 kg / day

Η = = = 84 .3

E rp =

N = 3 *3.2

C + ( 1/2 ) o2 → co

cal / mole
1- C + O2 → CO G = -94445

2- Al + (3/2) O2 → Al2 O3

E=

Energy consumed / kg produced in day

36
=

C.D =

Annual capacity of the plant = 135.9 *70*6*365

= 20833470 kg / year = 20833.5 t / year

37
 QUESTION NO. 16
In the electrolytic winning of aluminum, the overall reaction is
2Al2O3 + 3C = 4Al + 3CO2. The cell applied voltage is 4.5 V.
Calculate the consumption of Al2O3, carbon, and electric
energy (in Kwatt –hr) all per ton of produced aluminum; also
calculate the current efficiency if the daily production is 1.5
tons. The cell current is 200,000 amp, the atomic weight of Al
=27.

Solution
2 AL₂O₃ + 3 C → 4 AL + 3 CO₂
N →2 3 4 3
CONSUMPTION = PRODUCTION
N = WT /M.WTWT = N X M.WT

96500 → 27/ 3
I X T → THEO.WT
(2 X 10⁵ X 24 X 60 X 60 )→ X
THEO. WT = 1.6116 TON / DAY

EFFICIENCY = ACTUAL / THEORITICAL = 1.5 / 1.6116 = 93.1℅

ENERGY = I X V X T/ 1.5

38
 = 200, 000 X 4.5 X 24 / 1.5
ENERGY = 14,400 KW- HR / TON AL
2 ( 27X2 + 16 X 3) → 4 X 27
? ? → 1 TON
CONSUMPTION OF AL₂0₃
= ( 2 X (27 X2 + 16 X3 ))/ ( 4X 27 )
= 1.8 TON / TON OF AL
3 X 12 → ?
4 X 27 → 1 TON
COSUMPTION OF C = (3 X 12)/ (4 X 27)
= 0.33 TON / TON OF AL
2 X ( 27 X 2 + 16 X 3) → 4 X 27
?? → 1 TON
2 X 12 → 4 X27
?? → 1 TON

39
 QUESTION NO. 17
If we consider that the overall cell reaction in an aluminum
production cell is: 3C(s) + 2Al2O3(s)4Al(l) + 3 CO2(g)
and cell applied voltage is 4.1V, calculate the daily production
of aluminum; and per ton of produced aluminum, calculate
also the followings:

i- the consumption of Al2O3

ii- carbon consumption
iii- electric energy consumed (in Kwatt –hr)
Data: cell current = 200,000 amp

current efficiency = 94%

atomic weight of Al = 27.

Solution
If we consider that the overall cell reaction in an aluminium
production cell is :
3C +2Al2O3 →4Al+3CO
And cell applied voltage is 4.1, calculate the daily production of
aluminium; and per ton of produced aluminium calculate also
the followings: the consumption of Al2O3.

40
Electric energy consumed in Kw-hr
Data: cell current =200000 amp
Current efficiency=94%
Atomic weight of Al =27
Solution
3C+2Al2O3 →4Al +3CO2
96500 →27/3
200000*24*60*60 →X
Theoretical wt. =1611606gm /day
Actual wt. = efficiency *theoretical=0.94*1611606=1.515 ton/day
3C+2Al2O3→4Al+3CO2
2*(27*2+3*16) →X
4(27) →1ton
Therefore: consumption of Al2O3 =1.89ton/ton of Al
3*12 →X
4*27 →1 ton
Consumption of C= (3*12/4*27)*1 =0.33 ton of C per ton AL2O3
Energy consumed =I*V*t / = (200000*4.1*24)/1.5 =13120 Kw-
hr/ton of AL

41
 QUESTION NO. (18)
Calculate the total aluminum production cell voltage given the
following data:
 the operating cell temperature = 960oC
 the breakdown of contributions to the total cell voltage
is:
 across the anode = 0.61V,
 across the cathode = 0.26V,
 across the electrolyte = 1.87V,
 due to the anode effect = 0.17V.
 across the conductors between the cells = 0.12V, and
 across the conductors to rectifiers = 0.02V,
You can use the data given in the following table to calculate
the decomposition potential of Al 2O3 according to the
previously mentioned cell reaction.

Calculate in kwatt-hr the energy consumption per ton

aluminum across the anode, cathode, electrolyte, due to anode
effect, across the conductors between the cells, across the
conductors to rectifiers and in the decomposition of Al 2O3
according to the previously given cell reaction given the
following data:

 cell current = 145,000 amp

42
  the cell current efficiency = 85.6%
Data:

 H f (298K ) cP S(298K)

Constituent (Kcal / (cal / deg. (cal / deg.

mole) mole) mole)

Al2O3 - 400 28.3 12.2

CO2 -94.3 8.9 51.1

Al(s) --- 6.9 6.8

Al(1) --- 7.0 --

C --- 4.8 1.36

Lfusion= 2500 cal / mole for melting Al at 932K

Solution

(A)- 3C(s) + 2Al2O3(s)4Al(l) + 3 CO2(g)

T (K) =960 + 273 = 1233 (K)

H (1233) =H (298) +∫ cPdT

S (1233) =S (298) +∫ cP\T) dT

43
G (1233) = H (1233) - ( S (1233) *T)

G (1233) = - ZFE

H (1233) =H (298) +∫ cP1dT + L(Fusion)

+∫ cP2dT

H (298) = ∑ H (Product) - H (Reactant)

= 3 H (CO2) - 2 H (Al2O3)

= ( 3* -94000) – ( 2 * -400000
= 518000 cal \ mole

cP1= ∑ cP (Product) - cP(Reactant)

= 3 cP(CO2) + 4 cP(Al(s)) - 3 cP(C) – 2 cP(Al2O3)

= ( 3 * 8.9 ) + ( 4 * 6.9 ) – ( 3 * 4.8 ) – ( 2 * 28.3 )

= - 16.7 cal\deg. mole

cP2= ∑ cP (Product) - cP(Reactant)

= 3 cP(CO2) + 4 cP(Al(l)) - 3 cP(C) – 2 cP(Al2O3)

= ( 3 * 8.9 ) + ( 4 * 7 ) – ( 3 * 4.8 ) – ( 2 * 28.3 )

= - 16.3 cal\deg.mole

44
H (1233) =H (298) +∫ dT + 2500

+∫ dT

H (1233) = 505897 cal\mole

S (1233) =S (298) +∫ cP1\T)dT + ( L(Fusion)\T)

+∫ cP2\T)dT

S (298) = ∑ S (Product) - S (Reactant)

3C(s) + 2Al2O3(s)4Al(l) + 3 CO2(g)

S (298) = (4* S (Al(s))) + ( 3 * S (CO2)) – ( 2 * S (Al2O3))

– ( 3 * S (C))

= ( 4 * 6.8 ) + ( 3 * 51.1 ) – ( 2 * 12.2 ) – (3 * 1.36 )

= 152.02 cal\deg.mole

S (1233) =152.02 +∫ cP1\T)dT + ( L(Fusion)\T)

+∫ cP2\T)dT

= 152.02 +∫ \T)dT + ( L(Fusion)\T)

+∫ \T)dT
45
 S (1233) = 131.39 cal\deg.mole

G (1233) = H (1233) - ( S (1233) *T)

G (1233) = 505897 – ( 1233 * 131.39 )

G (1233) = 349128.6 cal\mole

G (1233) = 349128.6 = - ZFE = - 12 * 96500 * E

E = 1.24 volt

E (total) = 1.24 + 0.61 + 0.26 + 0.12 + 1.87 + 0.17 + 0.02

=4.29 volt

(B)- 96500 →27/3

145000*24*60*60 →X
Theoretical wt. =1168414.5 gm /day

Actual wt. = efficiency *theoretical=0.856*1168414.5

= 1000162 ton/day = 1 ton

(C)- Energy = I * V * t

Energy of decompose of Al2O3= 24 * 1.24 * 145000

= 4941600=494.6 KW.hr\ton of AL

46
Energy across the anode = 0.61 * 24 * 145000

= 2.123 KW.hr\ton of AL

Energy across the cathode = 0.26 * 24 * 145000

= 0.905 KW.hr\ton of AL

Energy across the electrolyte = 1.87 * 24 * 145000

= 6.508 KW.hr\ton of AL

Energy due to anode effect = 0.592 KW.hr\ton of AL

Energy across the conductors between the cells

= 0.418 KW.hr\ton of AL

Energy across the conductors to rectifiers

= 0.070 KW.hr\ton of AL
Then
Total Energy = 0.070 + 0.418 + 0.592 + 6.508 + 0.905 + 2.123
+ 494.6

Total Energy = 505.2 KW.hr\ton of AL

47
 QUESTION NO. (19)
Calculate the total cell voltage and the energy consumption per
ton aluminum produced given the following data:

 Cell current = 145,000 amp

 The cell current efficiency = 85.6%
 The operating cell temperature = 960 oC
 The breakdown of contributions to the total cell
voltage is given below:
 across the anode = 0.61V,
 across the cathode = 0.26V,
 across the electrolyte = 1.87V,
 due to the anode effect = 0.17V,
 across the conductors between the cells = 0.12V, and
 across the conductors to rectifiers = 0.02V,
you can use the data given by EllinghamDiagram to calculate
the decomposition potential of Al 2O3 according to the
following cell reaction:

3C(s) + 2Al2O3(s)4Al(l) + 3 CO2(g)

Calculate also the energy consumption across the anode,

cathode, electrolyte, due to anode effect, across the conductors
between the cells, across the conductors to rectifiers and in the
decomposition of Al2O3 according to the given cell reaction.
48
 Solution

3C(s) + 2Al2O3(s)4Al(l) + 3 CO2(g)

Getting ∆G from Ellingham Diagram

At T = 1233 K° T = 960 C°

(4/3)AL + O2  (2/3) AL2O3 ∆G° = - 85000 KJ  *3

C + O2  CO2 ∆G° = -400000 KJ  *3

Then total reaction will be

2AL2O3 + 3 C 3CO2 + 4 AL∆G° = 1350000 KJ

∆G° = 1350000 = - ZF∆E

∆E = (1350000) \ (12 * 96500 ) = 1.17 volt

E total = 1.17 + 0.61 + 0.26 + 1.87 +0.17 + 0.12 + 0.02

= 4.22 volt

49