Past exam of the MPhil in micro- and nanotechnology enterprise course of the University of Cambridge / 2017 / Paper 1 / Section B / 11 / v

First hold the production rate fixed, so total electric current remains $200\mathrm{A}$. If only the impure anode receives a factor $10^5$ increase in accessible area, its local current density becomes $0.002\mathrm{A}{\mathrm{m}}^{-2}$, far below $j_0=1\mathrm{A}{\mathrm{m}}^{-2}$. Extrapolating the large-current Tafel equation would give a negative anodic overpotential, which is physically the wrong regime. Near equilibrium the Butler-Volmer equation instead gives, in the same conditional two-electron model,The anode activation loss nearly disappears; the 1.20 V ohmic loss does not disappear. The cathode still operates close to its original transport limit if it is unchanged. The conditional kinetic model gives $V_{\mathrm{app}}\simeq 1.3286$ V for anode-only enlargement. Its anodic potential returns close to 0.34 V, making retention of noble silver and gold more favorable, while less noble nickel dissolution and lead sulfate formation remain relevant.

If both active areas increase by $10^5$ and their independent mass-transfer capacity scales by the same factor, both local kinetic losses become small and the conditional prediction is about $1.20005$ V. Porous internal area does not generally multiply an external diffusion-limited flux by $10^5$: pore access, ion depletion, tortuosity, electrical connectivity and slime blockage must be checked. If the specified 200 A/m² is instead held per true enlarged area, total current rises to $2\times 10^7$ A and the unchanged electrolyte resistance would give $1.2\times 10^5$ V, so this is an entirely different operating condition.

For the same refining rate and the same effective kinetic model, the anode-only estimate is therefore $1.3286\mathrm{V}$. The robust conclusion at fixed total current is reduced local activation polarization on the genuinely accessible enlarged surface, with an unchanged ohmic floor unless cell geometry or conductivity also changes. Increased geometric area alone does not prove a proportionate decrease in energy cost or improved purity. The distinct area and current conventions above specify how to interpret the prediction; they must not be mixed in one calculation.