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Analysis of a centreline failure of a lead alloy anode used in the copper electro-winning process
Engineering Failure Analysis, Volume: 120, Start page: 105057
Swansea University Authors: Ahmed Elrefaey, Johann Sienz
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DOI (Published version): 10.1016/j.engfailanal.2020.105057
Abstract
Thousands of lead anodes are currently used in the electro-winning of copper across the globe. The corrosion and the electrochemical performance of these anodes significantly affect the economy of the process. Premature failure of anodes is often a problem for the commercial operators of tank houses...
Published in: | Engineering Failure Analysis |
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ISSN: | 1350-6307 |
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Elsevier BV
2021
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2021-02-15T16:09:29.9079089 v2 55812 2020-12-03 Analysis of a centreline failure of a lead alloy anode used in the copper electro-winning process f65e29945dd6e621cd851af58802e502 Ahmed Elrefaey Ahmed Elrefaey true false 17bf1dd287bff2cb01b53d98ceb28a31 0000-0003-3136-5718 Johann Sienz Johann Sienz true false 2020-12-03 AERO Thousands of lead anodes are currently used in the electro-winning of copper across the globe. The corrosion and the electrochemical performance of these anodes significantly affect the economy of the process. Premature failure of anodes is often a problem for the commercial operators of tank houses. Recently, the authors were asked to advise on an unusual case where a lead alloy anode split at almost the centreline of the cross section. Different characterization techniques were employed to detect the cause of failure. The fractured samples were metallographically examined with an optical microscope and a Scanning Electron Microscope (SEM) equipped with Energy-Dispersive X-ray Spectroscopy (EDS) analysis. Different phase at the fracture surface were also identified by X-Ray Diffraction technique.The failure mechanism of this anode appears to be manganese contaminated electrolyte attacking the anode perimeter, leading to initial corrosion sites and compounded by subsequent exfoliation corrosion through inter-granular attack and further formation of manganese dioxide. The established practice of producing lead alloy anodes via rolling confers beneficial properties to the finished anodes. However, the resulting elongated grains can in some cases, where the electrolyte is contaminated with elements that are prejudicial to stable oxide layer formation, cause susceptibility to exfoliation corrosion. Journal Article Engineering Failure Analysis 120 105057 Elsevier BV 1350-6307 Exfoliation corrosion, Lead anode, Failure, Electro-winning, Microstructure 1 2 2021 2021-02-01 10.1016/j.engfailanal.2020.105057 COLLEGE NANME Aerospace Engineering COLLEGE CODE AERO Swansea University 2021-02-15T16:09:29.9079089 2020-12-03T10:00:01.9722528 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised Ahmed Elrefaey 1 Y. Gu 2 J.D. James 3 C. Kneen 4 I. Crabbe 5 Johann Sienz 0000-0003-3136-5718 6 55812__18830__7d86848de250480d8697b7bf1c2a6180.pdf 55812.pdf 2020-12-07T11:21:43.1281629 Output 5042714 application/pdf Accepted Manuscript true 2021-11-27T00:00:00.0000000 ©2020 All rights reserved. All article content, except where otherwise noted, is licensed under a Creative Commons Attribution Non-Commercial No Derivatives License (CC-BY-NC-ND) true eng http://creativecommons.org/licenses/by-nc-nd/4.0/ |
title |
Analysis of a centreline failure of a lead alloy anode used in the copper electro-winning process |
spellingShingle |
Analysis of a centreline failure of a lead alloy anode used in the copper electro-winning process Ahmed Elrefaey Johann Sienz |
title_short |
Analysis of a centreline failure of a lead alloy anode used in the copper electro-winning process |
title_full |
Analysis of a centreline failure of a lead alloy anode used in the copper electro-winning process |
title_fullStr |
Analysis of a centreline failure of a lead alloy anode used in the copper electro-winning process |
title_full_unstemmed |
Analysis of a centreline failure of a lead alloy anode used in the copper electro-winning process |
title_sort |
Analysis of a centreline failure of a lead alloy anode used in the copper electro-winning process |
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f65e29945dd6e621cd851af58802e502 17bf1dd287bff2cb01b53d98ceb28a31 |
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f65e29945dd6e621cd851af58802e502_***_Ahmed Elrefaey 17bf1dd287bff2cb01b53d98ceb28a31_***_Johann Sienz |
author |
Ahmed Elrefaey Johann Sienz |
author2 |
Ahmed Elrefaey Y. Gu J.D. James C. Kneen I. Crabbe Johann Sienz |
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Journal article |
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Engineering Failure Analysis |
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120 |
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105057 |
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2021 |
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10.1016/j.engfailanal.2020.105057 |
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Elsevier BV |
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description |
Thousands of lead anodes are currently used in the electro-winning of copper across the globe. The corrosion and the electrochemical performance of these anodes significantly affect the economy of the process. Premature failure of anodes is often a problem for the commercial operators of tank houses. Recently, the authors were asked to advise on an unusual case where a lead alloy anode split at almost the centreline of the cross section. Different characterization techniques were employed to detect the cause of failure. The fractured samples were metallographically examined with an optical microscope and a Scanning Electron Microscope (SEM) equipped with Energy-Dispersive X-ray Spectroscopy (EDS) analysis. Different phase at the fracture surface were also identified by X-Ray Diffraction technique.The failure mechanism of this anode appears to be manganese contaminated electrolyte attacking the anode perimeter, leading to initial corrosion sites and compounded by subsequent exfoliation corrosion through inter-granular attack and further formation of manganese dioxide. The established practice of producing lead alloy anodes via rolling confers beneficial properties to the finished anodes. However, the resulting elongated grains can in some cases, where the electrolyte is contaminated with elements that are prejudicial to stable oxide layer formation, cause susceptibility to exfoliation corrosion. |
published_date |
2021-02-01T04:10:17Z |
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11.031309 |