Cathode assembly including a barrier, system including the assembly and method for using same

Abstract

A cathode assembly, a system including the cathode assembly, and method of using the assembly and system are disclosed. The cathode assembly includes a conductive element and a barrier element proximate the conductive element. The assembly, system and method provide for improved metal powder formation. The system may be stationary or portable.

What is claimed is: 
     
         1 . A cathode assembly for electrowinning metal comprising:
 a suspension element;   a conductive element coupled to the suspension element; and   a barrier element having a plurality of holes.   
     
     
         2 . The cathode assembly of  claim 1 , further comprising at least one attachment element coupled to the suspension element and the barrier element. 
     
     
         3 . The cathode assembly of  claim 1 , wherein the barrier element comprises a material selected from the group of polyethylene, polystyrene, polyvinyl chloride, and polytetrafluoroethylene. 
     
     
         4 . The cathode assembly of  claim 1 , wherein the barrier element comprises one of a film, laminate or overlay. 
     
     
         5 . The cathode assembly of  claim 1 , wherein the conductive element comprises a metal starter sheet. 
     
     
         6 . The cathode assembly of  claim 7 , wherein the metal sheet comprises copper. 
     
     
         7 . The cathode assembly of  claim 1 , wherein the suspension element comprises material selected from the group consisting of copper, copper alloy, copper aluminum alloys, aluminum, stainless steel, titanium, gold, and combinations thereof. 
     
     
         8 . A system for electrowinning metal comprising:
 a cathode assembly comprising a suspension element, a conductive element coupled to the suspension element, and a barrier element having a plurality of holes;   an anode assembly;   an electrolyte solution between the anode assembly and cathode assembly; and   a tank containing electrolyte solution.   
     
     
         9 . The system of  claim 8 , wherein the electrolyte solution comprises one of a recycled solution, bleed solution, remediation solution, waste water solution, or acid mine drainage stream. 
     
     
         10 . The system of  claim 8 , wherein the barrier element comprises a material selected from the group of polyethylene, polystyrene, polyvinyl chloride, and polytetrafluoroethylene. 
     
     
         11 . The system of  claim 8 , wherein the barrier element comprises a film, laminate or overlay. 
     
     
         12 . The system of  claim 8 , wherein the electrolyte solution contains between 0.1 g/l and 2.5 g/l of metal ions. 
     
     
         13 . The system of  claim 8 , wherein the tank comprises a portable tank. 
     
     
         14 . A method of electrolytic recovery of metal comprising the steps of:
 providing an electrolyte solution;   electrowinning metal from the electrolyte solution using a cathode assembly, the cathode assembly comprising a conductive element and a barrier element proximate a surface of the conductive element, the barrier element having a plurality of holes; and   harvesting the metal in the form of metal powder.   
     
     
         15 . The method of  claim 14 , wherein the metal is copper. 
     
     
         16 . The method of  claim 14 , further comprising the step of recovering the electrolyte solution from a remediation site. 
     
     
         17 . The system of  claim 14 , wherein the barrier element comprises a material selected from the group of polyethylene, polystyrene, polyvinyl chloride, and polytetrafluoroethylene. 
     
     
         18 . The method of  claim 14 , wherein the barrier element comprises a film, laminate or overlay. 
     
     
         19 . The method of  claim 14 , wherein the concentration of ferrous iron ions in the electrolyte solution is controlled by the addition of a reducing agent. 
     
     
         20 . The method of  claim 14 , wherein the concentration of ferrous iron ions in the electrolyte solution is controlled by adjusting the pH of the electrolyte solution.