The utilization of modern automated control systems in copper cathode production offers the opportunity for remote access to control and regulate the electrolytic process parameters. This, in turn, enhances production efficiency while reducing energy costs. The significant parameters in copper electrolytic refining encompass the temperature and composition of the electrolyte, the circulation rate of the electrolyte, the level of sludge, and the frequency of short circuits occurring between the electrodes and the current density. These parameters directly impact the quantity and volume of cathode sludge. The occurrence of short circuits within the bath arises from the growth of dendrites, necessitating the monitoring of voltage, composition, and temperature of the electrolyte. Regular analysis of the electrolyte's composition and the accumulation of sludge volume at the bottom of the electrolyzer is also necessary. The intensification of the electrolysis process primarily involves increasing the current density, reducing the electrode spacing, enhancing the quality of electrodes, improving the electrolyte circulation system, and further mechanizing and automating the process and its auxiliary operations. These efforts contribute to increased productivity. The objective of this study is to expand the capabilities of automated process control systems by incorporating sludge level control sensors. This aims to mitigate irrecoverable losses resulting from dendritic sludge short circuits on the electrodes located in the lower section of the electrolyzer, utilizing new software. A sludge level control method to prevent short circuits has been investigated, and control software employing float-type level sensors has been developed. This measure is projected to decrease energy consumption by 15–20 % and can be effectively implemented in the production of electrolytic copper at the copper smelting plant in Lao Cai, Vietnam.
