# US 2013/0153435 A1 · High surface area cathode assembly, system including the assembly, and method of using same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0153435 A1 - Document ID: US20130153435A1 - Status: Published application - Kind: A1 - Application number: 13/331,661 - Filed: 2011-12-20 - Published: 2013-06-20 - Earliest claimed: 2011-12-20 - Assignees: Freeport-Mcmoran Corporation - Inventors: Scot P. Sandoval; Casey J. Clayton; Jason M. Morgan; Charles L. Bryce; Brett Waterman - Web page: https://patentgrep.com/patent/US20130153435A1 ## CPC - C25C 5/02: from solutions - C25C 1/12: of copper - C25C 7/02: Electrodes (consumable anodes for the refining the metals C25C1/00 - C25C5/00); Connections thereof - C25C: PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR ## Abstract A cathode assembly, a system including the cathode assembly, and method of using the assembly and system are disclosed. The cathode assembly includes high surface area material to allow efficient recovery of metal at reduced current densities at the cathode, which allows increased rates of metal recovery to be obtained, while maintaining desired properties of the electrowon metal. ## Claims ### Claim 1 A high surface area cathode assembly for electrowinning metal from solution, the cathode assembly comprising: a hanger bar; a high surface area material in contact with the hanger bar, the high surface area material having a surface area to volume ratio of about 0.05 ft2/in3 to about 10 ft2/in3; and a container about at least a portion of the high surface area material. ### Claim 2 (depends on 1) The high surface area cathode assembly of claim 1, wherein the high surface area material comprises material selected from the group consisting of metal hair wire, metal wool, metal fabric, metal foam, and conductive polymers. ### Claim 3 (depends on 2) The high surface area cathode assembly of claim 2, wherein the high surface area material comprises at least one of a copper mesh, a copper wool, a copper fabric, a copper foam, and a copper hair wire. ### Claim 4 (depends on 1) The high surface area cathode assembly of claim 1, wherein the surface area to volume ratio is about 0.1 ft2/in3 to about 5 ft2/in3. ### Claim 5 (depends on 1) The high surface area cathode assembly of claim 1, wherein the hanger bar comprises material selected from the group consisting of copper, copper alloy, copper aluminum alloys, aluminum, stainless steel, titanium, gold, and combinations thereof. ### Claim 6 (depends on 1) The high surface area cathode assembly of claim 1, wherein the container comprises a material selected from the group consisting of polyethylene, polystyrene, polyvinyl chloride, and polytetrafluoroethylene. ### Claim 7 (depends on 1) The high surface area cathode assembly of claim 1, wherein the container is a flow-through container comprising a plurality of voids and an open area of about 20% to about 80%. ### Claim 8 (depends on 1) The high surface area cathode assembly of claim 1, further comprising a connecting element coupled to the container and the hanger bar. ### Claim 9 (depends on 1) The high surface area cathode assembly of claim 1, further comprising a conductive element. ### Claim 10 (depends on 9) The high surface area cathode assembly of claim 9, wherein the conductive element comprises at least one conductive rod. ### Claim 11 (depends on 9) The high surface area cathode assembly of claim 9, wherein the conductive element comprises a metal sheet. ### Claim 12 (depends on 9) The high surface area cathode assembly of claim 9, wherein the conductive element comprises material selected from the group consisting of copper, copper alloy, copper aluminum alloys, aluminum, stainless steel, titanium, gold, and combinations thereof. ### Claim 13 A system for electrolytic recovery of metal, the system comprising: an anode assembly; a high surface area cathode assembly comprising a hanger bar, a high surface area material, the high surface area material having a surface area to volume ratio of about 0.05 ft2/in3 to about 10 ft2/in3, and a container about at least a portion of the high surface area material; and an electrolyte solution between the anode assembly and the cathode assembly; and a tank containing the electrolyte solution. ### Claim 14 (depends on 13) The system for electrolytic recovery of metal of claim 13, wherein the electrolyte solution comprises pregnant leach solution. ### Claim 15 (depends on 13) The system for electrolytic recovery of metal of claim 13, wherein the electrolyte solution further comprises iron ions. ### Claim 16 (depends on 13) The system for electrolytic recovery of metal of claim 13, wherein the system is a portable system and is placed near a source of the electrolyte solution. ### Claim 17 (depends on 13) The system for electrolytic recovery of metal of claim 13, wherein a portion of the anode assembly and a portion of the cathode assembly are in direct contact. ### Claim 18 (depends on 13) The system for electrolytic recovery of metal of claim 13, wherein the cathode assembly further comprises a conductor element coupled to the hanger bar. ### Claim 19 (depends on 13) The system for electrolytic recovery of metal of claim 13, wherein the electrolyte solution comprises a Cu/Fe3+ ratio of about 2 to about 6. ### Claim 20 (depends on 13) The system for electrolytic recovery of metal of claim 13, wherein the electrolyte solution comprises a Fe2+/Fe3+ ratio of about 2 to about 8. ### Claim 21 (depends on 13) The system for electrolytic recovery of metal of claim 13, wherein the high surface area material comprises at least one of a copper mesh, a copper wool, a copper fabric, a copper foam, and a copper hair wire. ### Claim 22 (depends on 13) The system for electrolytic recovery of metal of claim 13, wherein the cathode assembly further comprises a connecting element coupled to the hanger bar and the container. ### Claim 23 (depends on 13) The system for electrolytic recovery of metal of claim 13, wherein metal ions are recovered from the electrolyte solution in the form of metal powder. ### Claim 24 (depends on 23) The system for electrolytic recovery of metal of claim 23, wherein the metal powder is self-harvested from the cathode assembly. ### Claim 25 A method of recovering metal from an electrolyte solution, the method comprising the steps of: providing an electrolyte solution; electrowinning metal from the electrolyte solution using a high surface area cathode assembly having high surface area material with a surface area to volume ratio of about 0.05 ft2/in3 to about 10 ft2/in3; and harvesting the metal in the form of metal powder. ### Claim 26 (depends on 25) The method of recovering metal from an electrolyte solution of claim 25, wherein the step of electrowinning is performed at a constant voltage. ### Claim 27 (depends on 25) The method of recovering metal from an electrolyte solution of claim 25, wherein the electrolyte solution comprises one of a recycled solution, bleed solution, remediation solution, waste water solution, or acid mine drainage stream. ### Claim 28 (depends on 25) The method of recovering metal from an electrolyte solution of claim 25, wherein the electrolyte solution contains between 0.1 g/l and 2.5 g/l of metal ions. ### Claim 29 (depends on 25) The method of recovering metal from an electrolyte solution of claim 25, wherein the step of harvesting the metal in the form of metal powder comprises one of self-harvesting or dynamic harvesting.