Electrowinning Cell Insulating Board
Flame-Retardant Resin Concrete Insulation for EW Cell Safety & Efficiency
The electrowinning cell insulating board is a critical safety and performance component installed in copper electrowinning and electrorefining tankhouses. Manufactured from flame-retardant resin concrete with a smooth gelcoat surface, it provides reliable electrical insulation, thermal barrier performance and corrosion resistance in the harsh acidic electrolysis environment.
Proper insulation directly impacts current efficiency, operational safety and equipment service life. Our insulating boards are engineered to meet the demanding requirements of hydrometallurgical operations, providing stable performance over years of continuous service.
Custom Sizing Information
Our insulating boards are custom-fabricated to your exact cell dimensions. For an accurate quotation and proper fit, please provide:
1. Drawings of electrolytic cell, anode plate and cathode plate
2. Number of cathode plates per cell
3. Inter-cell busbar drawings
4. Same-pole distance (electrode spacing)
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Core Functions
The insulating board performs three essential functions in EW cell operation:
- Electrical Insulation Prevents current leakage and electrical grounding faults between the cell structure and electrode frame, maintaining stable current distribution and protecting both personnel and equipment.
- Thermal Barrier Reduces heat transfer from the electrolyte to the cell body, minimizing heat loss and helping maintain consistent electrolyte temperature for optimal copper deposition efficiency.
- Corrosion & Chemical Protection Resists acid mist, electrolyte splashes and continuous chemical exposure, protecting underlying cell structures from corrosion and extending overall system life.
Material & Construction
Flame-Retardant Resin Concrete
Our insulating boards are manufactured from high-quality flame-retardant resin concrete (polymer concrete), composed of vinyl ester resin binder and mineral aggregates. The surface is finished with a smooth gelcoat layer for enhanced corrosion resistance and easy cleaning.
Key material characteristics:
- Excellent electrical insulation properties
- Good mechanical strength and structural stability
- Superior resistance to sulfuric acid and chloride environments
- Flame-retardant formulation for improved safety
- Low thermal conductivity for heat retention
- Smooth, non-porous gelcoat surface
Technical Specifications
| Item | Specification |
|---|---|
| Base Material | Flame-retardant resin concrete (polymer concrete) |
| Surface Finish | Smooth gelcoat layer |
| Volume Resistivity | ≥ 3.5 × 10¹² Ω·cm |
| Dielectric Strength | ≥ 5 kV/mm |
| Compressive Strength | ≥ 80 MPa |
| Flexural Strength | ≥ 20 MPa |
| Thermal Conductivity | 0.3 – 0.5 W/m·K |
| Acid Resistance | Excellent - suitable for sulfuric acid and chloride environments |
| Flame Retardancy | Flame-retardant formulation |
| Max Operating Temperature | 80 – 100°C (continuous) |
| Thickness | Customized to project requirements |
| Installation | Custom-fabricated to cell dimensions |
| Typical Service Life | 8 – 15 years (depending on operating conditions) |
Key Advantages
- Reliable Electrical Insulation
With volume resistivity of ≥ 3.5 × 10¹² Ω·cm and dielectric strength of ≥ 5 kV/mm, the board effectively prevents current leakage and electrical faults, ensuring stable current distribution across the cell and protecting operating personnel. - Energy & Heat Retention
Low thermal conductivity (0.3 – 0.5 W/m·K) reduces heat loss from the electrolyte to the cell structure, helping maintain consistent operating temperature and reducing energy consumption in continuous electrowinning operations. - Excellent Corrosion Resistance
Resin concrete with gelcoat surface withstands the harsh tankhouse environment - including sulfuric acid mist, electrolyte splashes and continuous chemical exposure - maintaining its insulating and structural properties over years of service. - High Mechanical Strength
Compressive strength ≥ 80 MPa provides robust structural performance, resisting the mechanical stresses of electrode loading, crane operations and normal plant activity without cracking or deformation. - Flame-Retardant Safety
Formulated with flame-retardant properties to enhance safety in industrial environments, reducing fire risk in the tankhouse. - Custom Precision Fit
Each board is custom-fabricated to your exact cell dimensions and layout, ensuring proper fit and consistent insulating performance across your entire tankhouse.
Application Scenarios
- Copper electrowinning (EW) cell insulation
- Copper electrorefining (ER) cell insulation
- Zinc, nickel, cobalt and other non-ferrous metal electrowinning
- New tankhouse construction projects
- Existing cell refurbishment and insulation upgrades
- Acidic electrolysis processes requiring electrical insulation
Design & Customization
- Custom Dimensioning
Insulating boards are custom-fabricated to your specific cell dimensions and layout. We work from your drawings or on-site measurements to ensure precise fit. - Early EPC Involvement
Integration during the early EPC design stage ensures optimal performance and compatibility with other cell components, such as busbars, electrode frames and cell liners. - Thickness & Configuration Options
Board thickness and configuration are selected based on your voltage requirements, mechanical load conditions and thermal insulation needs.
Cell Type & Size Required
Insulating boards must be cut according to specific cell dimensions and slot designs.
Early Design Involvement Helps
Integration in early EPC stage ensures optimal performance and compatibility with other components.
Optional Reinforcements
For heavy-duty usage, optional fiberglass mesh or rigid support backing is available.
Packaging & Transportation
Flat-Pack Bundling
Boards are stacked with anti-slip layers and wrapped in waterproof film.
Weight-Sensitive Handling
Though light in weight, these boards require care to avoid edge damage. Custom crates available for bulk orders.
Global Shipment Ready
We support air or sea freight with certificates like MSDS and RoHS upon request.
FAQ: Still Have Questions?
Q1: Can these be installed on existing cells during refurbishment?
A: Yes. We offer insulation board solutions for both new construction and existing cell refurbishment projects, with custom sizing to match your current cell dimensions.
Q2: What is the typical service life?
A: Under normal operating conditions, resin concrete insulating boards typically last 8–15 years. Actual service life depends on temperature, chemical concentration and mechanical wear. We recommend periodic inspection to assess condition.
Q3: How does resin concrete compare with PVC or PP insulation boards?
A: Resin concrete offers higher mechanical strength, better thermal stability and longer service life than PVC or PP. It is more suitable for heavy-duty industrial electrolysis applications where structural performance and durability are important.
Q4: What standards do your products follow?
A: Our resin concrete products are manufactured in accordance with HG/T 4752-2014 "Integrally cast vinyl resin concrete electrolytic cells" industry standard.
Q5: Do you provide end cell insulators as well?
A: Yes. We offer end cell insulators (Au-end insulators) in PP, PVC and FRP materials, custom-sized to your cell dimensions.
Q6: Do you provide installation guidance?
A: Yes. We provide installation instructions and technical support. For large tankhouse projects, on-site installation guidance can be arranged.
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