Composite electrode for electrolytic processes

Claim 2

In a process for producing a composite electrode for use in an electrolytic cell comprising a valve metal substrate and an outer surface layer comprising ruthenium dioxide, the improvement which comprises providing: (a) a barrier layer comprising a platinum group metal directly on the substrate and (b) between the barrier layer and outer surface layer an intermediate layer comprising a metallic electroplated deposit consisting of ruthenium and iridium, said intermediate layer containing at least a small but effective amount of iridium to reduce ruthenium dissolution during use in said cell, and said intermediate layer being at least partially oxidized.

Claim 3

A process according to claim 1, wherein the metallic electroplated layer of ruthenium and iridium is subjected to a temperature of about 400° C. to about 900° C. for about 5 to about 60 minutes in an oxidizing atmosphere to at least partially oxidize the surface of said layer before depositing the outer surface layer.

Claim 4

A composite electrode for use as an insoluble anode in an electrolytic cell, and especially useful in a process for electrowinning a metal, which comprises an electroconductive substrate having on at least a portion of the surface thereof a multilayer coating, said coating consisting essentially of: (a) a barrier layer directly on the substrate; (b) a non-electroplated outer surface layer comprising ruthenium dioxide; and (c) an intermediate layer between the barrier layer and outer surface layer comprising an electroplated metallic deposit of ruthenium and iridium, said intermediate layer being at least partially oxidized.

Claim 5

A composite electrode for use as an insoluble anode in an electrolytic cell, and especially useful in a process for electrowinning a metal, which comprises an electroconductive substrate having on at least a portion of the surface thereof a multilayer coating, said coating consisting essentially of: (a) a barrier layer directly on the substrate; (b) a non-electroplated outer surface layer comprising ruthenium dioxide; and (c) an intermediate layer between the barrier layer and outer surface layer comprising an electroplated metallic deposit of ruthenium and iridium, said intermediate layer being at least partially oxidized.

Claim 6

In a process for electrowinning a metal from solution, the improvement which comprises using as the anode a composite electrode, according to claim 3.

Claim 7

The process according to claim 4, wherein the electrowinning process is carried out at an anode current density of up to about 50 mA/cm 2 and the ruthenium-iridium intermediate layer contains at least about 1% iridium.

Claim 8

A process according to claim 4, wherein the process is for the electrowinning of nickel.

Claim 9

A process according to claim 6, wherein the nickel contains cobalt.

Claim 10

A process according to claim 4, wherein the electrowinning process is carried out at an anode current density greater than about 50 mA/cm 2 and the ruthenium-iridium intermediate layer contains at least about 2% iridium.

Claim 11

A process according to claim 4, wherein the electrowinning process is carried out at an anode current density greater than about 50 mA/cm 2 and the ruthenium-iridium intermediate layer contains about 4% iridium.

Claim 12

A composite electrode of claim 3, wherein the intermediate layer contains at least a small but effective amount of iridium for reduction of ruthenium loss during operation of the electrolytic cell.

Claim 13

A composite electrode according to claim 3, wherein the barrier layer is selected from at least one of the group consisting of a platinum group metal, gold, and alloys, mixtures, intermetallics and oxides thereof and the group further consisting of silicides, nitrides and carbides of at least one of the components of the substrate.

Claim 14

A composite electrode for use in an electrolytic cell, and especially useful as an anode in a process for electrowinning nickel, which comprises a valve metal substrate having on at least a portion of the surface thereof a multilayer coating, said coating consisting essentially of: (a) a barrier layer directly on the substrate, said barrier layer comprising a platinum group metal; (b) a non-electroplated outer surface layer comprising ruthenium dioxide; and (c) an intermediate layer between the barrier layer and outer surface layer comprising an electroplated metallic deposit of ruthenium and iridium, said intermediate layer being at least partially oxidized directly at the surface adjacent to the ruthenium dioxide outer surface layer.

Claim 15

A composite electrode for use in an electrolytic cell, and especially useful as an anode in a process for electrowinning nickel, which comprises a valve metal substrate having on at least a portion of the surface thereof a multilayer coating, said coating consisting essentially of: (a) a barrier layer directly on the substrate, said barrier layer comprising a platinum group metal; (b) a non-electroplated outer surface layer comprising ruthenium dioxide; and (c) an intermediate layer between the barrier layer and outer surface layer comprising an electroplated metallic deposit of ruthenium and iridium, said intermediate layer being at least partially oxidized directly at the surface adjacent to the ruthenium dioxide outer surface layer.

Claim 16

A composite electrode according to claim 12, wherein the platinum group metal is selected from the group consisting of palladium, iridium, rhodium and platinum.

Claim 17

A composite electrode, according to claim 13, wherein the platinum group metal is electroplated on the substrate.

Claim 18

A composite electrode according to claim 14, wherein the platinum group metal is a flash coating of iridium.

Claim 19

A composite electrode, according to claim 13, wherein the platinum group metal is palladium and said barrier layer is at least about 0.05 μm in thickness.

Claim 20

A composite electrode according to claim 13, wherein the platinum group metal is platinum and the barrier layer is treated in an oxidizing medium.

Claim 21

A composite electrode according to claim 12, wherein the outer surface layer consists essentially of at least 80% RuO 2 .

Claim 22

A composite electrode according to claim 18, wherein the outer surface layer contains up to about 20% non-active component.

Claim 23

A composite electrode according to claim 18, wherein the outer surface layer is essentially free of an added non-active component.

Claim 24

A composite electrode according to claim 12, wherein the intermediate layer is subjected to a heat treatment to oxidize at least a portion of the outer surface of said layer.

Claim 25

A composite electrode according to claim 21, wherein the heat treatment is effected at a temperature of about 400° C. to about 900° C. in an oxidizing atmosphere.

Claim 26

A composite electrode according to claim 12, wherein the valve metal substrate comprises titanium.

Claim 27

A composite electrode according to claim 12, wherein the platinum group metal-containing barrier layer has a thickness of small but effective amount to preserve the current carrying capacity of the electrode under O 2 evolution up to about 0.5 μm.

Claim 28

A composite electrode according to claim 12, wherein the intermediate layer contains at least a small but effective amount of iridium to suppress ruthenium dissolution during operation of the electrolytic cell.

Claim 29

A composite electrode according to claim 12, wherein the intermediate layer has a thickness of at least about 0.1 μm.

Claim 30

A composite electrode according to claim 12, wherein the intermediate layer contains about 1% up to about 36% iridium.

Claim 31

A composite electrode according to claim 12, wherein the ruthenium dioxide layer is developed by decomposition and oxidation of a ruthenium compound deposited in a vehicle on the intermediate layer.

Claim 32

A composite electrode according to claim 12, wherein the ruthenium dioxide outer layer is developed at a temperature of 315° C. to 455° C. in an oxidizing atmosphere.

Claim 33

A composite electrode according to claim 12, wherein the ruthenium content of the ruthenium dioxide outer layer is at least about 0.1 mg/cm 2 .

Claim 34

A composite electrode according to claim 12, wherein the valve metal substrate is a surface layer on a more conductive metal.

Claim 35

A composite electrode for use in an electrolytic cell, and especially useful as an anode in a process for electrowinning a metal, which comprises a valve metal substrate having on at least a portion of the surface thereof a multilayer coating, said coating consisting essentially of: (a) a barrier layer directly on the substrate, said barrier layer comprising a platinum group metal of at least about 0.05 μm in thickness; (b) a non-electroplated outer surface layer comprising ruthenium dioxide and having a ruthenium content of at least about 0.1 mg/cm 2 ; and (c) an intermediate layer between the barrier layer and outer surface layer, said intermediate layer comprising an electroplated metallic deposit of ruthenium and iridium, the iridium component of said deposit being at least a small but effective amount to reduce ruthenium dissolution during operation of said electrolytic cell, said intermediate layer having a thickness of at least about 0.1 μm, and said intermediate layer being at least partially oxidized directly at the surface adjacent to the ruthenium dioxide outer surface layer.

Claim 36

A composite electrode for use in an electrolytic cell, and especially useful as an anode in a process for electrowinning a metal, which comprises a valve metal substrate having on at least a portion of the surface thereof a multilayer coating, said coating consisting essentially of: (a) a barrier layer directly on the substrate, said barrier layer comprising a platinum group metal of at least about 0.05 μm in thickness; (b) a non-electroplated outer surface layer comprising ruthenium dioxide and having a ruthenium content of at least about 0.1 mg/cm 2 ; and (c) an intermediate layer between the barrier layer and outer surface layer, said intermediate layer comprising an electroplated metallic deposit of ruthenium and iridium, the iridium component of said deposit being at least a small but effective amount to reduce ruthenium dissolution during operation of said electrolytic cell, said intermediate layer having a thickness of at least about 0.1 μm, and said intermediate layer being at least partially oxidized directly at the surface adjacent to the ruthenium dioxide outer surface layer.