Comparison of effective parameters for copper powder production via electrorefining and electrowinning cells and improvement using DOE methods

The influences of cupric ion concentration (5–35 g/L), current density (500–2000 A/m²), circulation rate of the electrolyte solution (15–120 mL/min), and temperature (25–60°C) on the physical and chemical properties of copper powders obtained in electrolysis cells were investigated. Two industrial processes, electrorefining (ER) cells with a synthetic electrolyte and electrowinning (EW) cells with an original solution of copper mineral leaching, were utilized to produce copper powders. Finally, the statistical full factorial method of design of experiments (DOE) was employed to investigate the interaction or the main effects of processes. The results show that increasing the copper concentration and temperature can increase the grain size, apparent density, and electrical energy consumption. On the other hand, increasing the current density and circulation rate of the electrolyte can decrease them. This production process is optimized via DOE to control the interactive and main effects to produce copper powders with favorable properties.