Although advanced numerical methods exist and have been applied with success in a broad range of engineering domains (hydrodynamics, aerodynamics, structural mechanics, heat transfer, …), the use of these methods for electrochemical applications is very limited. One of the main reasons for this is the complexity of the processes that govern electrochemical cells. The main processes are: electrochemical kinetics at electrodes, hydrodynamics of the electrolytic solution, mass transport of ions and uncharged species due to convection, diffusion and migration, and eventually also homogeneous reactions, gas evolution, heat generation in the bulk and at the electrode-electrolyte interfaces.

The core technology of Elsyca is based upon the idea to consider an electrochemical system as a closed system of electric sources, connections, electrodes, electrode reactions and electrolyte solutions. An example is shown in the figure: The current distribution in both electrochemical cells (tanks filled with an electrically conductive, water based electrolyte) is determined not only by what happens in the tank, but also by the connections to the sources, the internal electrical resistance of the coil to be surface treated (e.g. steel or aluminium) and the possible leackage or stray currents to earth.

An electrochemist will mainly focus on electrode reactions and electrolytical solutions in a simple and well defined geometry (e.g. a lab setup with rotating disc electrode). Elsyca engineers incorporate the same electrolyte bath characteristics in their models but focus also on the electrotechnical, thermal and mechanical aspects of the process at the same time: voltage drops in wires and electrodes, current density distributions, layer thickness distributions, growth or dissolution of electrodes, heat removal and mass transport. This theoretical-scientific approach provides the real industrial added-value, because it permits to simulate parameter variations (e.g. electric currents, cell geometry, electric circuitry, etc.) thus enabling to work at maximum effectiveness.

The numerical model developed by Elsyca takes into account the following phenomena:

• ohmic drop in the electrolyte solution;
• cathodic polarization including the effects of the additives;
• cell configuration
• active surface fraction of the different pattern zones
• electrical contacting method and injected current.

This modeling approach is commonly denoted as the ‘potential model’. This model forms the base of the key technology of Elsyca, embedded in a set of software tools to model, predict and optimize a variety of electrochemical processes:
 

• Elsyca PlatingMaster enables to predict current density, removed metal from anodes and deposited layer thickness distributions
• Elsyca ECMMaster enables to predict workpiece shape changes, based on the potential model, taking into account phenomena like electrochemical cell configuration, anodic and cathodic reaction polarisation behaviour, moving cathode tools, topology changes,etc.

Besides the potential model, Elsyca also developed a multi-ion model, taking into account mass transfer in the electrolyte solutions. The model is used for extremely advanced engineering services. 

The combination of our simulation technology and engineering competences enables Elsyca to provide advanced engineering solutions for the complete electrochemical industry. Elsyca continuously strives to further extend and fine-tune this technology using direct feedback from the advanced engineering projects and research projects with several leading players in the field.
 

Examples of Elsyca's Fundamental Research Studies can be explored by clicking here.