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Analysis of a centreline failure of a lead alloy anode used in the copper electro-winning process

Ahmed Elrefaey, Y. Gu, J.D. James, C. Kneen, I. Crabbe, Johann Sienz Orcid Logo

Engineering Failure Analysis, Volume: 120, Start page: 105057

Swansea University Authors: Ahmed Elrefaey, Johann Sienz Orcid Logo

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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...

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Published in: Engineering Failure Analysis
ISSN: 1350-6307
Published: Elsevier BV 2021
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URI: https://cronfa.swan.ac.uk/Record/cronfa55812
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spelling 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
author_id_str_mv f65e29945dd6e621cd851af58802e502
17bf1dd287bff2cb01b53d98ceb28a31
author_id_fullname_str_mv 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
format Journal article
container_title Engineering Failure Analysis
container_volume 120
container_start_page 105057
publishDate 2021
institution Swansea University
issn 1350-6307
doi_str_mv 10.1016/j.engfailanal.2020.105057
publisher Elsevier BV
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Uncategorised{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Uncategorised
document_store_str 1
active_str 0
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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score 10.998775

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