Abstract—PV energy prices are declining rapidly. To take advantage of the benefits of those prices and lower the carbon footprint, operational practices must be modified. Undoubtedly, it challenges the electrowinning practice to operate at constant current throughout the day. This work presents a technology that contributes in providing modulation capacity to the electrode current distribution system. This is to raise the day time dc current and lower it at night. The system is a triple intercell bar that operates in current-source mode. The design is a capping board free dogbone type of bar that ensures an operation free of short circuits, hot swapability repairs and improved current balance. This current-source system eliminates the resetting currents circulating in equipotential bars. Twin auxiliary connectors are added to the main connectors providing secure current paths to bypass faulty or impaired contacts. All system conductive elements are positioned over a baseboard offering a large heat sink area to the ventilation of a facility. The system works with lower temperature than a conventional busbar. Of these attributes, the cathode current balance property stands out and is paramount for day/night modulation and the use of photovoltaic energy. A design based on a 3D finite element method model predicting electric and thermal performance under various industrial scenarios is presented. Preliminary results obtained in an electrowinning facility with industrial prototypes are included. Keywords—Electrowinning, intercell bars, PV energy, current modulation. I. INTRODUCTION HE current technological breakthrough in PV systems has caused a drop in electricity prices. Since 2010, the price of PV generation has drop from USD 210 to USD 18 [1]. This rapid decrease in energy prices will come in hand with a revolution in the way the industry takes advantage of PV energy cost. Depending on the area in which the PV plant is set, PV plants supply energy to the grid between 9 am and 5 pm (see Fig. 1). The proper operation of copper electrowinning (EW) cells requires good current balance to ensure low dispersion in copper deposition on the cathode plates over time. This requires an intercell bar with intrinsic resilience to contacts wear, electrode misalignment and electrolytic impurities [2], This work was supported by the Chilean research fund CONICYT under FONDAP project Nº 15110019. Eduardo P. Wiechmann F. is with the Electrical Department of University of Concepcion, Chile (corresponding author, phone: 56-41-2204775; e-mail: eduardo.wiechmann@udec.cl). Jorge A. Henriquez M., Pablo E. Aqueveque N. and Luis G. Muñoz Q.are with the University of Concepción, Chile (e-mail: jorhenriquez@udec.cl, pablo.aqueveque@udec.cl, luismunoz@udec.cl). [3]. This paper presents an improved current distribution system that fulfills this purpose by forcing current balance among cell cathodes [4]. The equalization of equivalent resistances is accomplished thanks to a series electrical connection. The system comprises a polymer composite baseboard, S-shaped copper main busbars and U-shaped secondary bars. Fig. 1 Daily generation pattern 09-16-2017 of the Great North Interconnected System (SING). Fossil fuels based (grey) and PV energy (orange). Dotted line represents the projected change if EW facilities if modulated to utilize PV energy (±25%) This work presents a design of a dog-bone type system, designated as Triple Intercell Bar (TIB). The design criteria ensure a colder operation to reduce copper corrosion and annealing. The operational temperature of the system improves based on the removal of the capping board. Zaldívar Mining Company (Antofagasta, Chile) is currently evaluating industrial prototypes. II. THE BUSBAR TOPOLOGY The busbar topology should meet strict requirements to modulate the process and incorporate PV energy, according to the following hierarchy: 1. Operate with high current balance. 2. Ensure current flow facing anomalies. 3. Control metallurgical short circuits. 4. Ensure copper deposit facing contact loss. 0 2 4 6 8 10 12 14 16 18 20 22 24 0 0.2 0.4 0.6 0.8 1 1.2 0 2 4 6 8 10 12 14 16 18 20 22 24 0 0.2 0.4 0.6 0.8 1 1.2 Hours [h] Energy generated [p.u.] Hours [h] Energy generated [p.u.] Eduardo P. Wiechmann, Jorge A. Henríquez, Pablo E. Aqueveque, Luis G. Muñoz Triple Intercell Bar for Electrometallurgical Processes: A Design to Increase PV Energy Utilization T World Academy of Science, Engineering and Technology International Journal of Materials and Metallurgical Engineering Vol:13, No:8, 2019 427 International Scholarly and Scientific Research & Innovation 13(8) 2019 ISNI:0000000091950263 Open Science Index, Materials and Metallurgical Engineering Vol:13, No:8, 2019 waset.org/Publication/10010675