Empirical models predicting the purity of electrowon tellurium have been de
veloped using data from 36 pilot-plant trials. Based on these models, a num
erical optimization of the process was performed to identify conditions whi
ch minimize the total contamination in Pb and Se while reducing electrical
consumption per kilogram of electrowon tellurium. Results indicate that pro
duct quality can be maintained and even improved while operating at the muc
h higher electroplating production rates obtained at high current densities
. Using these same process settings, the electrical consumption of the proc
ess can be reduced by up to 10 pet by operating at midrange temperatures of
close to 50 degrees C. This is particularly attractive when waste heat is
available at the plant to help preheat the electrolyte feed. When both Pb a
nd Se are present as contaminants, the most energy-efficient strategy invol
ves the use of a high current density, at a moderate temperature with high
flow, for low concentrations of TeO2. If Pb is removed prior to the electro
winning process, the use of a low current density and low electrolyte feed
concentration, while operating at a low temperature and moderate flow rates
, provides the most significant reduction in Se codeposition.