Metal Dissolving Device, Metal Dissolving Treatment Method, and Use Thereof

Abstract

A metal dissolution apparatus and process are disclosed. The apparatus comprises a reactor, a metal inlet for receiving a metal-containing substance, a solution inlet for receiving a metal dissolution solution, and a solution outlet for supplying a metal dissolution solution containing dissolved metal. The apparatus has a length and a height, and the height is less than the length. The process includes supplying a metal dissolution solution into a first position of the reactor containing the metal-containing substance, flowing the metal dissolution solution through the reactor, dissolving metal from the metal-containing substance into the metal dissolution solution, and discharging the metal dissolution solution from the reactor.

Description

Technical Field

[0001] The present disclosure generally relates to an apparatus for dissolving or leaching metals from metal-containing substances. The dissolved or leached metals can be useful in the manufacture of consumer, industrial, or agricultural products.

Background Art

[0002] Metal dissolution equipment is used for the dissolution or leaching of metals from metal-containing substances. Once dissolved or leached, the metals can be further processed and / or separated for use in the manufacture of different chemicals or materials for batteries, electroplating, animal feed, fertilizers, dentifrices, agricultural sprays, etc.

[0003] Conventional metal dissolution processes are either batch or continuous.

[0004] In a conventional batch process, conventional metal dissolution equipment includes a stirred batch tank. The tank is filled with metal and a dissolution solution and is left standing for a while (periodic or continuous stirring may be included). Once the metal is sufficiently dissolved, all of the contents of the tank are removed.

[0005] However, in a stirred tank system, due to the tendency of large particles to sink towards the bottom of the tank due to their weight, the large particles are not well stirred and the dispersion in the dissolution solution becomes non-uniform.

[0006] In a conventional continuous process, a dissolution column is filled with a metal-containing substance. A dissolution solution is supplied into the column at a specific location, flows through the metal-containing material in the column, dissolves the metal in the passing solution, and is then removed from the column at another location. The solution removed from the column contains dissolved metal. The solution can be processed to extract the dissolved metal and subsequently recycled back into the column in a continuous loop process.

[0007] To maximize the amount of metal dissolved, it is desirable for the reactor to incorporate a packed bed of metal components. The challenge associated with using a dissolution solution in a process with a packed bed of metal components (also called a packed bed process), regardless of whether it is a batch or continuous process, is to ensure the mixing and uniform dispersion of the chemical composition of the metal dissolution solution across the column. As a typical design practice for a dissolution column that helps to achieve the mixing and uniform dispersion of all the chemicals in this solution, either horizontally or vertically within the column, is to size the column diameter to be approximately 10 times the size of the largest metal-containing particles, and then size the column height to be approximately 4 to 8 times the column diameter. Thus, the conventional column height-to-diameter ratio is typically between 4 to 1 and 8 to 1, where the ratio is calculated by dividing the height by the diameter. The column diameter (width) is constant throughout. This convention is known and relied upon in the art to generally help achieve sufficient uniformity in the mixing and dispersion of all the chemicals in the solution (either horizontally or vertically) across the column. Without such uniformity in the mixing and dispersion of the solution, areas of the column with low concentrations of the solution reactants may form, and / or a large portion of the unreacted metal dissolution solution may pass through and out of the column. This can potentially result in inhibiting or otherwise preventing the ability to dissolve the metal to the desired amount or target. An elongated column helps to prevent, to some extent, the backflow of the solution within the column.

[0008] To be effective and efficient in the dissolution or leaching of metal-containing substances, the dissolution column must also have a sufficient height to allow for a sufficiently high flow rate of the solution within the column and also a sufficiently high target residence time. For example, the column may need to be at least 6 - 8 meters in height. Such a height is essential from the perspective of the kinetics of the metal dissolution reaction as follows. The solution must be flowed through the metal-containing material at a threshold rate or velocity to promote the dissolution of the metal. The solution must have a threshold time within the column so that it dissolves a sufficient amount of metal before exiting the column and remains in contact with the metal-containing substance (otherwise, the full dissolution capacity of the solution cannot be utilized).

[0009] For these reasons, conventional columns must have a height that allows the solution to flow through the column at an optimal rate and with an optimal residence time while maintaining the correct height-to-diameter ratio to ensure the uniformity of mixing and dispersion of all the chemicals in the solution across the column.

[0010] However, under certain processing conditions, the optimal height that aids in achieving uniform mixing and dispersion may differ from the optimal height that achieves the minimum solution velocity and residence time. Furthermore, while using a taller column has the incentive of increasing the amount of metal-containing substance that can be processed at one time, if the column is too tall, there is a risk that the solution reagent concentration will drop to a lower level at the top of the column, slowing down the dissolution reaction, and thus the overall volume of the metal-containing substance in the column cannot be effectively utilized for dissolution.

[0011] Due to the above design requirements, the column is typically symmetric, has a continuous diameter (sometimes with a conical section at the bottom), and the column is assembled on-site using supports external to the reactor itself to prevent the tall and slender column from falling over.

[0012] Solutions are desired to solve the problems and trade-offs in using columns to dissolve or leach metals from metal-containing substances.

Brief Description of the Drawings

[0013] With reference to the accompanying drawings, embodiments of the present disclosure will be described herein by way of example only.

Figure 1

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Figure 3A

Figure 3B

Figure 3C

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Embodiments for Carrying Out the Invention

[0014] What is described in this specification are metal melting systems, apparatuses, and processes.

[0015] The metal dissolution device has a height that is less than its length. The metal dissolution device can be a box. The device can include a reactant dispersion device 170 to help homogenize the flow of the chemical components of the dissolution liquid by fluid pressure. The dispersion device can be, for example, a porous pipe, a through nozzle, or a raised bottom.

[0016] As used herein, the term "height" refers to the vertical dimension of the device. As used herein, the term "length" refers to the longest non-diagonal horizontal dimension of the device. As used herein, the term "width" refers to the shortest horizontal dimension of the device.

[0017] The height of the device may be less than the height of a dissolution column of equivalent capacity (e.g., less than about 6 to 8 meters). The ratio of the height to the length of the device may be less than 1, where the ratio is calculated by dividing the height by the length. In an embodiment, the metal dissolution device is a box.

[0018] The height, length, and width of the device may be proportional to each other such that the device is self-standing. For example, the ratio of the height to the length of the device may be 1 or less for it to be self-standing. This means that the device does not tip over even if the base of the device is tilted from the horizontal up to 45 degrees during use (while containing the metal-containing material and the dissolution liquid). In an embodiment, a self-standing device must be able to remain standing safely during use without any structural support outside the space defined by the device. In an embodiment, a self-standing device is configured to have a center of mass that is at a height less than half the width of the device. The term "self-standing" does not exclude the device being fixed to a base or support structure to help prevent movement in the horizontal / sideways direction and / or for additional safety.

[0019] The device may have a sufficiently flat and large base. The height and base of the device may be dimensioned so that the device can be installed on a flat surface such as a structural foundation without the need for peripheral infrastructure such as elevated structural elements or external supports to install, fix, support, and / or stabilize the device. The device may also be configured to fit within a standard shipping container. Shipping containers generally have dimensions of approximately 4 meters in height by 5 meters in width by 12 meters in length. That is, the device may be sized and shaped so as to be transportable within the frame of a standard shipping container. For example, the device may be substantially rectangular in shape and may be 4m in height × 4m in width × 11m in length. The reactor 110 may be rectangular in plan view.

[0020] The metal melting device may be a reactor. The reactor may have a simple modular and substantially rectangular design. Generally, a modular structure refers to a structure that can be mostly manufactured and / or assembled at a location away from its intended destination, can be easily transported to its intended location, can reduce the relatively few installation, finishing, and / or assembly operations required on-site, and / or can be easily assembled on-site at one time. The modular reactor may be configured to have a shape that integrates or connects with the reverse shape of the same modular reactor. The reactor may have eight corners. Such a substantially rectangular design can maximize the melting treatment volume obtained from dimensions that can be efficiently factory-manufactured and easily shipped by standard means of transportation. The metal melting device may provide a reactor having a substantially box-shaped structure. A device having such a structure may have a sufficiently low height to facilitate maintaining uniform leaching treatment conditions within the device reactor.

[0021] The metal dissolution device may comprise one or more divided parts, where the divided part(s) divide(s) the device into a plurality of reactors. Each of the plurality of reactors may define a separate dissolution section or zone of the device. The reactor may be divided or segmented in the width direction and / or the length direction. The reactor may comprise a plurality of divided parts. By forming these separate dissolution sections or zones with the divided parts, the metal dissolution device may be configured to separately dissolve or leach different metal-containing substances, and it may be possible to separately collect the loaded metal dissolution solutions.

[0022] Alternatively, the metal dissolution device may be composed of a plurality of reactors. Each of the plurality of reactors may be a modular reactor that is physically separated and not connected to any of the other modular reactors. In such an embodiment, it is not necessary for each individual reactor to be self-supporting or to have a height-to-length ratio of less than 1, but the device as a whole may comprise a number of reactors arranged adjacent to each other such that the device as a whole, when considered as a whole, is self-supporting or has a height-to-length ratio of less than 1. In an embodiment, each reactor may be a separate module that can be transported individually and / or attached to other reactors. In other embodiments, the reactors may be installed and arranged within a container, and the device comprises a combination of the container and the reactors arranged therein.

[0023] The apparatus described herein may include a reactant dispersion device 170 that helps to equalize the flow of the metal dissolution solution across the apparatus by fluid pressure. The reactant dispersion device 170 can help avoid the dependence on backpressure created by a packed bed of metal-containing material (used in conventional dissolution columns) to provide flow uniformity (e.g., a column having a height-to-diameter ratio between about 4 to 1 and 8 to 1, where the ratio is calculated by dividing the height by the diameter). The apparatus according to the present disclosure may have a sufficiently low height to maintain spatially uniform processing conditions at a scale suitable for commercial sizes, such as achieving scale-up, when connected to a dispersion device to help enforce the uniformity of the reactant flow by fluid pressure. Since the leaching process described herein may be stable within a narrow operating window such as acidity, pH, peroxide-to-acid ratio, temperature, metal strength (also known as metal concentration in solution), etc., it can be important to maintain uniformity of conditions on a large scale. The reactant dispersion device 170 that can enable such uniformity of conditions may comprise a porous pipe, a through nozzle, a bottom-up that may be perforated or connected to a through nozzle, a series of metal dissolution solution inlets, or a combination thereof. The reactant dispersion device 170 may be located within the main body of the reactor that also contains the leaching solution.

[0024] Figures 1 and 2 show a metal dissolution apparatus 100 according to an embodiment of the present disclosure. In the embodiments shown in Figures 1 and 2, the metal dissolution apparatus 100 includes a reactor 110. Although reference is made to the reactor 110 with respect to its structural features, their locations, and their operations, those features, locations, and operations may be similarly applied to the apparatus in substantially the same manner as specified with respect to the reactor 110.

[0025] Referring to FIGS. 1 and 2, the metal melting apparatus 100 includes a reactor 110. The reactor 110 has a length and a height where the height is less than the length. The reactor 110 may be self - standing. The reactor 110 includes a metal inlet 120 positioned at a first position of the reactor 110 for supplying a metal - containing substance (not shown in FIG. 1) to the reactor 110. The metal inlet 120 may be positioned along the height of the reactor 110 and optionally may be positioned within the upper portion 112 of the reactor 110. As shown in FIG. 2, the metal inlet 120 may be an opening in the upper portion 112 of the reactor 110. The reactor 110 also includes a solution inlet 130 positioned at a second position of the reactor 110 for supplying a metal - melting solution into the reactor 110, and a solution outlet 140 positioned at a third position of the reactor 110 for discharging the metal - melting solution from the reactor 110.

[0026] Furthermore, the reactor 110 may include a ventilation system (see, for example, the ventilation outlet 160 shown in FIG. 1) positioned at a fourth position of the reactor 110. The ventilation system may include at least one gas inlet and at least one gas outlet configured and positioned to supply a gas flow into the reactor 110 and exhaust gas from the reactor 110. For example, the ventilation system may include ventilation air entry through the opening at 120, or through the inlet port 121, or through dedicated air - entry openings (s) (not shown) around the roof portion, and may include a ventilation outlet 160, optionally two or more outlets 160, positioned along the height and length of the reactor and optionally positioned within the upper portion 112 of the reactor 110.

[0027] The ventilation system may be an exhaust gas treatment system. The ventilation system may further comprise a gas capture system. Gases such as hydrogen, oxygen, or combinations thereof may be emitted during the dissolution or leaching of the metal-containing substance. The gas may be emitted by the corrosion of the metal-containing substance by an acid (e.g., hydrogen may be emitted). The gas may be emitted from reactions related to oxides such as peroxides (e.g., oxygen may be emitted). The resulting gas may carry a liquid aerosol into the reactor 110 and may need to be washed in a gas scrubber (e.g., a scrubber or a mist eliminator, etc.). The production of hydrogen is often diluted before being discharged into the atmosphere and may need to be recovered, or captured, for use, in order to maintain a concentration below the lower explosive limit of hydrogen. Alternatively, air may need to be squeezed out so that hydrogen can be recovered and / or captured for use.

[0028] The reactor 110 may comprise a transport system such as the transport system 150 shown in FIG. 1. The transport system 150 is connected to the reactor 110 to supply the metal-containing substance to the metal inlet 120. The transport system 150 comprises a conveyor that transports the metal-containing substance into the reactor 110 via the inlet port 121, as shown. The transport system 150 may additionally or alternatively comprise a robotic system that transports the metal-containing substance to the reactor 110 via the inlet port 121. The robotic system may be attached along the edge of the length of the reactor 110. Alternatively, the metal-containing substance may be transported loose, in a bag or drum, or placed on a pallet, such that the drum may tip over, the bag may break, or free material may accumulate at the inlet port.

[0029] Reactor 110 has a height that is less than the length of the reactor. For reactor 110, the term "height" as used herein refers to the vertical dimension of the reactor. The term "length" as used herein refers to the longest non-diagonal horizontal dimension of the reactor. The term "width" as used herein refers to the shortest horizontal dimension of the reactor. Reactor 110 may have a height that is less than the height of the dissolution column (e.g., less than about 6 to 8 meters). Reactor 110 may have a height-to-length ratio of less than 1, where the ratio is calculated by dividing the height by the length.

[0030] The height, length, and width of the reactor may be proportional to each other for the reactor 110 to stand on its own. For example, the ratio of the length to the height of the reactor 110 may be 1 or more for it to stand on its own. This means that even during the use of the reactor 110 (which contains the metal-containing material and the dissolution solution), the reactor 110 will not tip over even if the base of the reactor 110 is tilted from the horizontal state up to 45 degrees. In an embodiment, the self-standing reactor 110 must be able to remain safely standing during use without any structural support outside the space defined by the reactor. In an embodiment, the self-standing reactor is configured to have a center of mass that is less than half the width of the reactor and at a height. Despite being self-standing, the reactor 110 may still be usefully fixed to a base or support structure for preventing movement in the horizontal / sideways direction and for safety. The reactor 100 may have a sufficiently flat and large base. The height and base of the reactor 110 are dimensioned so that the reactor 110 can be installed on a flat surface such as a structural foundation without the need for a surrounding infrastructure such as elevated structural elements, external supports, etc. that are required to install, fix, support, and / or stabilize the reactor 110. The reactor 110 may also be configured to fit within a standard shipping container. A shipping container generally has dimensions of approximately 4 meters in height by 5 meters in width by 12 meters in length. That is, the reactor 110 may be sized and shaped so that it can be transported within the frame of a standard shipping container. For example, the reactor 110 may be substantially rectangular in shape and may be 4 m in height × 4 m in width × 11 m in length. The reactor 110 may be rectangular in plan view.

[0031] In an embodiment, the reactor 110 is modular (not shown in FIGS. 1 and 2). The modular reactor 110 may be configured to be assembled with other modular reactors 110 that have similar or substantially identical shapes and dimensions. The metal melting apparatus 100 may include a plurality of modular reactors 110. In such an embodiment, the individual reactors 110 do not necessarily have to be self-standing or have a height-to-length ratio of less than 1. However, the apparatus 100 itself may include a number of reactors arranged adjacent to each other such that, when taken as a whole, the apparatus 100 is self-standing or has a height-to-length ratio of less than 1. Each reactor may be a separate module that can be transported individually and / or attached to other reactors 110. The reactors 110 may be attached to each other using fasteners such as nuts and bolts. In other embodiments, the reactors 110 may be installed and arranged within a container, and the apparatus 100 may include a combination of the container and the reactors arranged therein.

[0032] The reactors of the present disclosure may be formed from metal, cement, plastic, or combinations thereof. The reactors may be formed from fiber reinforced plastic (FRP), high density polyethylene (HDPE), cross-linked HDPE, polyvinyl chloride (PVC), chlorinated PVC (CPVC), polypropylene (PP), etc. The reactors may be formed from metal or concrete and may be surrounded by FRP, rubber, or other plastics.

[0033] Reactor 110 is provided with a solution inlet 130 and a solution outlet 140. The solution inlet 130 and the outlet 140 may each be provided with a plurality of openings within the outer wall of the reactor 110. The solution inlet 130 may be at a second position along the height and length of the reactor 110, and optionally may extend along the length of the reactor in a state where the openings are positioned at regular intervals along the length of the reactor, or may be at a second position along the height and width of the reactor 110, and optionally may extend along the width in a state where the openings are positioned at regular intervals. The solution outlet 140 may be at a third position along the height and length of the reactor, and optionally may extend along the length of the reactor, or may be at a third position along the height and width of the reactor, and optionally may extend along the width.

[0034] As shown in FIGS. 1 and FIG. 2, the solution inlet 130 may extend along the length of the reactor 110 within the lower part or bottom 111 of the reactor. The solution outlet 140 may also extend along the length of the reactor 110 within the upper part or top 112 of the reactor. Positioned in this way, the inlet 130 and the outlet 140 may provide a flow of the metal-dissolving solution that moves to the lower part of the reactor, flows upward into the reactor, passes through the metal-containing material within the reactor, and reaches the upper part of the reactor. The solution may then exit the reactor through the outlet 140. The flow of the solution may be countercurrent to the flow of the metal-containing substance. In this case, the solution flows into the reactor 110 at a lower position and can flow upward through any metal-containing substance that is moving downward by gravity when the metal substance at the lower part within the reactor 110 is dissolving and shrinking. Thereafter, the enriched leachate may be discharged from the upper part of the reactor.

[0035] Alternatively, the solution inlet 130 may extend along the length of the reactor 110 within the upper or top portion 112 of the reactor, and the solution outlet 140 may extend along the length of the reactor within the lower or bottom portion 111. Positioned thus, the inlet 130 and outlet 140 may provide a flow of the metal dissolution solution that moves from the upper portion of the reactor and flows downwardly to the lower portion of the reactor. The flow of the solution may be co-current with the flow of the metal-containing material, in which case the solution flows into the reactor 110 at the upper portion and, as the material in the lower portion of the reactor 110 dissolves and shrinks, flows downwardly through any metal-containing material that is also moving downwardly by gravity, and then the solution may be discharged from the lower portion of the reactor. Optionally, the solution inlet 130 and solution outlet 140 may be positioned along opposite widths or at the ends of the reactor 110, in which case each may be positioned in the upper portion 112 or lower portion 111 of the reactor. Positioned thus, the inlet 130 and outlet 140 may serve to provide a flow of the metal dissolution solution that is cross-current to the flow of the metal-containing material, in which case the solution flows into the reactor 110 from one end and, as the material in the lower portion of the reactor 110 dissolves and shrinks, flows across any metal-containing material that is moving downwardly by gravity and then the solution may be discharged from the other side.

[0036] The solution inlet 130 may comprise a series of openings extending along the outer length of the reactor 110. The openings of the solution inlet 130 may receive the solution from the manifold 131. The manifold 131 may be tapered as it extends along the length of the reactor 110. The taper may serve to supply a uniform flow of the solution to each of the openings of the inlet 130. The manifold 131 may have individual conduits connecting the manifold 131 to each of the openings of the solution inlet 130.

[0037] Figure 3A shows a front perspective inner view of the interior of the reactor 110 of FIGS. 1 and 2. The reactor 110 is located within the reactor 110 and includes a plurality of pipes 172 having holes or perforations 174 therein (shown in FIG. 3B), which is a device 170 that helps enable the uniformity of the flow of reactants through the reactor 110 by fluid pressure. The pipes 172 are connected to the solution inlet 130 (shown in FIG. 2) to receive the metal dissolution solution and supply the solution into the reactor 110. Each pipe may be connected to the opening of the solution inlet 130. The porous pipes 172 may assist in the more uniform dispersion and / or flow of the solution across the vertical and / or horizontal aspects of the reactor 110. The perforations 174 are located only in specific areas of the pipes and can help control the dispersion and / or flow rate of the solution within the reactor 110. For example, the perforations 174 may be located only along the bottom of the pipes 172, including those shown in FIG. 3B. Positioning the perforations 174 along the bottom of the pipes 172 can assist in first dropping the solution into the reactor 110 (see the arrow in FIG. 3B) and then flowing it upward within the reactor around the pipes. The pipes 172 may extend across the inner width of the reactor 110. The pipes 172 may be configured, for example, to help disperse the metal leachate with substantially spatial uniformity across the reactor by impeding the flow of the solution, such that the solution is forced to disperse as it passes upward and around the metal pipes 172. The pipes 172 may be detachable. The use of detachable pipes may make it possible to manufacture or design the pipes as consumables (if the service life is shorter, the use of thinner gauges and less expensive materials is possible). Also, since the pipes are not fixed to the reactor 110 such that they cannot be removed or moved, the labor of welding may also be less. For example, less expensive materials may also be used to manufacture pipes with shorter service lives and / or reduced initial costs. The use of detachable pipes may also facilitate the maintenance and inspection of the pipes 172 or the reactor 110, including the bottom of the reactor under the pipes.Furthermore, the solution outlet 140 may comprise a series of outlets extending along the outer length of the reactor 110, supported and supplied by a manifold 141 for discharging the metal leachate.

[0038] FIG. 3C shows a front perspective view of a portion of the metal dissolution apparatus 100 in an embodiment of the present disclosure. The apparatus 100 includes a reactor 110 and a reactant dispersion device 170. The dispersion device 170 has a raised bottom 176 with a through nozzle 178. The chemical reactant enters into the cavity defined by the raised bottom 176. The reactant then emerges from the cavity into the main part of the reactor containing the metal through the through nozzle 178. The reactant may enter into the cavity defined by the raised bottom 176 via a pipe (not shown). The distribution of the through nozzles 178 across the raised bottom 176 may serve to better or more uniformly disperse the flow of the reactant across the width and length of the reactor 110.

[0039] FIG. 4 shows a metal dissolution apparatus 200 according to an embodiment of the present disclosure. In the embodiment shown in FIG. 4, the metal dissolution apparatus 200 includes a reactor 210. While reference is made to the reactor 210 with respect to its structural features, their locations, and their operations, those features, locations, and operations may be similarly applied to the apparatus in substantially the same manner as specified with respect to the reactor 210.

[0040] Referring to FIG. 4, the metal melting apparatus 200 is divided by a dividing section 220. The dividing section 220 divides the apparatus into a plurality of reactors 210. Each of the plurality of reactors 210 is defined in a separate melting section or zone 230 of the apparatus 200. The reactor 210 may be divided or segmented in the width direction (as shown in FIG. 4) and / or the length direction (not shown). The reactor 210 may include a plurality of dividing portions (not shown). By forming these separate melting sections or zones 230 with the dividing section 220, the metal melting apparatus 200 may be configured to separately melt or leach different metal-containing substances and / or may be able to separately collect the charged metal melt. When the apparatus 200 includes a plurality of reactors, the reactors 210 may operate in parallel, in series, or in a combination of both. When the reactors are arranged / operated in series, the leachate may sequentially pass from one reactor to the next. This can help minimize excess reagents in the final discharge solution from the last reactor in the series. In an embodiment, the reactors 210 may be connected by conduits to allow the metal melt to pass between the reactors.

[0041] The metal melting apparatus described in this specification can be used to perform metal melting treatment. The treatment may comprise one or more of the following steps. The metal-containing substance may be introduced into the metal melting apparatus described in this specification through a metal inlet. The metal melting solution may be supplied into the lower part of the apparatus with substantially spatial uniformity when the apparatus contains the metal-containing substance. The solution may be supplied into the apparatus through a plurality of porous pipes so as to be more uniformly dispersed throughout the apparatus. The metal melting solution may flow through the apparatus under a relatively low hydrostatic pressure load while maintaining a substantially uniform metal melting state over the length and height of the apparatus. The dimensions and shape of the apparatus having a height less than its length may result in a relatively low hydrostatic pressure load and may make it possible to maintain the metal melting state substantially uniformly over the length and height of the apparatus with a lower vertical gradient. The metal melting state may comprise pH, ratio of leaching reagent, temperature, dissolved metal concentration, or a combination thereof, and is maintained within a desired range for the dissolved metal.

[0042] The treatment described in this specification may be a batch process. It is generally understood by those skilled in the art of the present application that the term "batch process" refers to a process without a steady state (also called stable) of processing conditions. As used herein, a "batch process" refers to a process in which one or more processing conditions change over time, and such processing conditions include (i) the ratio of the metal melting solution to the metal-containing substance, (ii) the concentration of the reagent in the metal melting solution, (iii) temperature, pressure, pH, or flow rate, (iv) the concentration of the dissolved metal in the metal melting solution, and (v) the concentration of metal ions in the leachate recycled to the reactor.

[0043] The processes described in this specification may be continuous processes. It is generally understood by those skilled in the art of the present application that the term "continuous" refers to a process intended to achieve or achieve a relatively steady state (such that the processing conditions are stable) over the entire duration of operation. In order to make the metal dissolution process continuous, all of the following processing conditions must ultimately achieve the following stability: (i) the amount and concentration of reagents in the metal dissolution solution introduced into the metal dissolution apparatus, (ii) the minimum or greater amount and / or surface area of the metal-containing substance dissolved within the apparatus, (iii) the amount and concentration of metal ions in the leachate recycled to the reactor, and (iv) the amount and concentration of the introduced metal dissolution solution exiting the apparatus. Each processing condition must generally or remain stable with respect to each of the other processing conditions. Even if there are variations in the processing conditions, if they are within the test error / operating tolerance, they are still considered to be in a steady state or stable. Such variations do not impair the fact that the leaching process is continuous.

[0044] The metal of the metal-containing substance may be dissolved or leached into the metal dissolution solution. Thus incorporated with the dissolved or leached metal, the metal dissolution solution may subsequently be discharged from the top of the apparatus. The metal dissolution solution may be recycled or recycled and returned into the apparatus. The apparatus may be provided with a pump useful for circulating the metal dissolution solution within the apparatus and optionally useful for recycling.

[0045] The metal-containing substances (also referred to as feedstocks) described herein may comprise relatively pure metals that are easily soluble, impure metals, metal alloys, intact or cut cathodes or cathode sheets, metal pellets, rounds, or crowns, metal shots, scraps, or shredded metals, metal powders or briquettes, or combinations thereof. The metals may include nickel, cobalt, nickel / cobalt alloys, ferronickel, manganese, copper, or combinations thereof. The apparatuses and processes described herein may receive a feedstock of very pure metal as the metal-containing substance. The apparatuses and processes described herein may be configured to receive other types of feedstocks as the metal-containing substance(s), including electrolytically produced, or hydrogen-reduced, or pure metals produced by the carbonyl process, metals of inferior purity produced by pyrometallurgy or other means, mixtures of different metals, metal alloys such as ferronickel or those that may be derived from spent catalyst treatment, or other metal feedstocks.

[0046] The metal dissolution solutions described herein may contain an acid in an aqueous solution. The metal dissolution solutions described herein may contain an acid and an oxidizing agent in an aqueous solution. The acid may be sulfuric acid, hydrochloric acid, nitric acid, or combinations thereof. The oxidizing agent may be added as a solid, liquid, or gas. The oxidizing agent may be SO2 / oxygen, peroxide, oxygen, an oxidizing agent containing or composed of H+ or cations containing or composed of the dissolved metal, an oxidizing agent containing or composed of anions containing or composed of sulfates, or combinations thereof, and combinations thereof. An oxidizing agent comprising cations composed of H+ or the dissolved metal and containing anions composed of sulfates may be selected when making the chemicals of the metal-containing battery. The metal dissolution solutions described herein may contain sulfuric acid regardless of the presence or absence of an oxidizing agent in the aqueous solution. The metal dissolution solution may contain an aqueous solution of sulfuric acid and peroxide.

[0047] Metals dissolved or leached from the metal-containing material can be used in the manufacture of consumer products (e.g., batteries, toothpaste), industrial products or processes (e.g., batteries, electroplating) or agricultural products (e.g., feed, fertilizers, sprays, etc.). Metal sulfates may result from metals dissolved or leached from the metal-containing material. Metal sulfates may include nickel sulfate, zinc sulfate, cobalt sulfate, manganese sulfate, copper sulfate or combinations thereof. Thus formed, the metal sulfates may be further processed and / or recovered through processes occurring downstream of the metal dissolution device and may be used in the manufacture of batteries (e.g., nickel sulfate), electroplating (e.g., nickel sulfate), animal feed, fertilizers, toothpaste or agricultural sprays (e.g., zinc sulfate), as mineral processing flotation agents (copper sulfate), or combinations thereof.

[0048] Any one or more of the metal dissolution devices, processes and uses of the present disclosure may provide any one or more of the following.

[0049] The metal dissolution apparatus may provide a reactor having a simple modular and substantially rectangular design. The modular reactor may be configured to have a shape that integrates or connects with the reverse shape of the same modular reactor. The reactor may have eight corners. Such a substantially rectangular design can maximize the dissolution processing volume obtained from dimensional sizes that can be efficiently factory manufactured and easily shipped through standard transportation means. The metal dissolution apparatus may provide a reactor having a substantially box-shaped structure. When a reactor having such a form is connected to a series of metal dissolution liquid inlets or other devices dispersed so as to help enforce the uniformity of the flow of the metal dissolution liquid by fluid pressure, it may have a sufficiently low height to provide the ability to maintain spatially uniform processing conditions on a scale suitable for commercial sizes such as achieving scale-up. As described above, since the processes described herein may be stable within a narrow operating range such as acidity, pH, peroxide-to-acid ratio, temperature, metal strength (also known as metal concentration in solution), etc., it may be important to maintain uniformity of conditions on a large scale.

[0050] As a result of the size and shape of the reactor, the metal dissolution apparatus may require fewer interconnecting pipes, transport systems, equipment, valves, etc. Further, the metal dissolution apparatus may result in a high metal dissolution capacity throughput module per unit cost being obtained (e.g., up to 40,000 tons / year of metal equivalent depending on the feedstock type).

[0051] A low reactor height relative to its length can result in a metal dissolution apparatus that requires a less complex material supply system (e.g., solution inlets), a lower building height (e.g., less than 6 meters), a lower pressure drop / pump capacity, a lower hydrostatic / geostatic load (from the pressure of the metal-containing substance and the solution during reactor use), a lower hoist conveyor for loading metal, or a combination thereof. Further, the metal dissolution apparatus can achieve more uniform processing conditions with a lower vertical gradient, can be easier to operate and / or maintain, can be installed more easily and / or quickly, can handle a wide range of feedstocks and sizes (pellets, cathodes, round, crown, etc.) of metal-containing substances, or a combination thereof.

[0052] Described herein are metal dissolution systems and processes for dissolving metal. The system includes a metal dissolution apparatus according to an embodiment of the present disclosure. The system may further include additional structures such as a recirculation tank, a buffer tank, a storage tank, or a combination thereof.

[0053] Figures 5A - 5D show a metal dissolution system according to an embodiment of the present disclosure that includes a metal dissolution apparatus. In the embodiments shown in Figures 5A - 5D, system 300 includes a metal dissolution apparatus that includes a reactor 310. Although reference is made to reactor 310 with respect to its structural features, their locations, and their operations, those features, locations, and operations can be applied equally well to any metal dissolution apparatus in substantially the same manner as specified with respect to reactor 310.

[0054] The metal dissolution system 300 shown in FIGS. 5A-5D can be used to perform batch processing, as described herein. The system 300 may be used to leach or dissolve metal from a wide range of metal-containing substances (also referred to as "metal feed" in FIGS. 5A-D if not otherwise). The system 300 includes a reactor 310, a recirculation tank 320, and a buffer tank 330. The reactor 310 has a metal dissolution liquid inlet 340 at one end and a metal dissolution liquid outlet 350 at the other end. The outlet 350 is connected to the recirculation tank 320. The system 300 also includes a metal dissolution liquid recirculation loop 360 that supplies the solution to a recirculation loop 360 for taking the solution in the recirculation tank 320 and recirculating it back into the reactor 310. The solution in the recirculation tank 320 may start as water. However, once the leaching process begins, the solution in the recirculation tank 320 becomes a semi-loaded (also known as semi-enriched) metal dissolution liquid received from the reactor outlet 350. The semi-loaded metal dissolution liquid exits the recirculation tank and enters the recirculation loop 360, where it is returned into the reactor at its inlet 340. The loop 360 is formed by the reactor outlet 350, the recirculation tank 320, a recirculation tank outlet 370 connected to the reactor inlet 340, and the reactor inlet 340. The reactor inlet 340 also receives a new metal dissolution liquid having an acidity expected to be higher than that of the recirculating semi-loaded metal dissolution liquid (or also referred to as "reagent feed" in FIGS. 5A-5D). The new metal dissolution liquid and water or semi-loaded metal dissolution liquid may be mixed before being supplied into the reactor 310 through the inlet 340. When the solution from the recirculation tank / loop is mixed with the new metal dissolution liquid, a third solution is formed. By mixing these solutions together, the third solution comes to have a lower acidity than the new metal dissolution liquid alone and a high flow rate / volume. The lower acidity of the third solution serves to protect against excessive dissolution of the metal-containing substance near the inlet 340. The higher volume / flow rate of the third solution serves to achieve the desired level in the mass transport for dissolution more than what the new metal dissolution liquid alone can achieve.The entire semi - load solution exiting the reactor 310 can be recycled back into the reactor 310 via the recycle tank 320 and loop 360. The recycle process may be continued for several cycles so that the amount of metal dissolved in the solution in the recycle tank 320 increases over time until the target / threshold level of dissolved metal in the solution of the recycle tank is reached.

[0055] The systems described herein, such as the system shown in FIGS. 5A - 5D, may be performed under batch - type processing conditions.

[0056] In an embodiment, the metal dissolution batch process involves circulating a metal dissolution solution through a metal dissolution apparatus containing a metal-containing substance. The metal dissolution solution may be circulated through the apparatus with substantially spatial uniformity. The metal dissolution solution may be circulated through the apparatus with substantially spatial uniformity under a relatively low hydrostatic pressure load while maintaining a substantially uniform metal dissolution state over the length, width, and height of the apparatus. The metal dissolution solution may be supplied into the apparatus through a reactant dispersion device within the reactor, such as a plurality of porous pipes, so as to disperse the solution more evenly throughout the apparatus. Other reactant dispersion devices are possible, such as a manifold inside the reactor, an injection nozzle penetrating the floor or side wall of the reactor. The metal dissolution state may include pH, ratio of leaching reagent, temperature, dissolved metal concentration, or a combination thereof. The process may include dissolving metal from the metal-containing substance into the circulating metal dissolution solution. The metal dissolution solution may be circulated into the apparatus at a first position and out of the apparatus at a second position. The first position may be located at the lower part of the apparatus, and the second position may be located at the upper part of the apparatus. The process may further include circulating the metal dissolution solution through a recirculation loop. The recirculation loop may include circulating the metal dissolution solution (with dissolved metal ions therein) from the reactor at the second position to a recirculation tank and from the recirculation tank to the reactor at the first position. The process may further include supplying a metal dissolution reagent into the metal dissolution solution when the solution circulates from the recirculation tank to the reactor at the first position. The process may further include circulating the metal dissolution solution through a recirculation loop, gradually increasing the concentration of dissolved or leached metal in the metal dissolution solution by dissolving metal from the metal-containing substance into the metal dissolution solution, and finally forming a loaded metal dissolution solution. The loaded metal dissolution solution may contain a specific or desired concentration of dissolved or leached metal. Once the loaded metal dissolution solution is formed, the batch process is complete. The process may subsequently include flowing the loaded metal dissolution solution from the recirculation tank to a buffer tank. The process may further include flowing the loaded metal dissolution solution from the buffer tank for further downstream processing.

[0057] In an embodiment, the metal dissolution system 300 shown in FIGS. 5A - 5D is operated under batch - type processing conditions. The metal dissolution solution may be prepared from a reagent containing sulfuric acid and hydrogen peroxide, and the processing temperature may be below the temperature at which substantial decomposition of hydrogen peroxide occurs (generally considered to be less than 85°C).

[0058] The process includes feeding a metal - containing substance (metal feed) into the reactor 310 through the upper part 380 of the reactor 310 and filling the recirculation tank 320 with water (FIG. 5A). The water is then circulated through the system 300 using a recirculation loop 360 where fresh metal dissolution solution is fed into the recirculation loop 360 in front of the reactor inlet 340. The fresh metal dissolution solution is formed from fresh acid and optionally an oxidizing agent added from the recirculation tank 320 into the water / half - loaded metal dissolution solution (FIG. 5B). Over time, as the fresh / half - loaded metal dissolution solution circulates through the reactor 310, the concentration of dissolved or leached metal (e.g., in the form of metal ions) in the recirculating solution increases (FIG. 5C). The recirculation loop serves to provide mass transport for dissolution.

[0059] Once the recycled solution reaches the desired dissolved or leached metal concentration, a loaded metal solution is considered to have been formed. Recycling and the introduction of fresh metal solution may be stopped (Figure 5D). By stopping the addition of fresh metal solution, the leaching process occurring within the reactor / device can be effectively stopped. The loaded metal solution from the recycle tank 320 (also known as Pregnant Leach Solution: PLS) may be fed into the buffer tank 330 via the recycle tank outlet 370. The recycle tank 320 and the buffer tank 330 may be separated by valves that prevent the PLS from moving from one tank to the other until switched. The buffer tank 330 is then disconnected from the recycle tank 320, and the loaded metal solution from the buffer tank 330 is sent further downstream for further processing. While the buffer tank loaded metal solution is being sent downstream, the leaching process may be restarted (Figures 5A - 5D). Restarting the leaching process may include filling the recycle tank 320 with water (Figure 5A), and then, once a sufficient amount of water is in the recycle tank 320, restarting the supply of fresh metal solution into the reactor 310 in combination with the water.

[0060] Figures 6A - 6E show a metal dissolution system according to an embodiment of the present disclosure, comprising a metal dissolution device having the metal dissolution device described herein. In the embodiment shown in Figures 6A - 6E, the system 400 comprises a metal dissolution device 410 having a reactor. While referring to the reactor 410 with respect to its structural features, their positions, and their operations, those features, positions, and operations may be equally applicable to any other device in substantially the same manner as specified with respect to the reactor 410.

[0061] The metal dissolution system 400 shown in FIGS. 6A-6E can be used to perform batch processing as described herein. The system 400 can be used to leach or dissolve metals from a wide range of metal-containing materials (or also referred to as "metal feed" in FIGS. 6A-6E). The system 400 includes a reactor 410, a first recirculation tank 420, and a second recirculation tank 430. The reactor 410 has a metal dissolution liquid inlet 440 at one end and a metal dissolution liquid outlet 450 at the other end. The outlet 450 alternately switches connections between the first recirculation tank 420 and the second recirculation tank 430. The system 400 includes a first metal dissolution liquid recirculation loop 460 that takes a semi-loaded (alternatively, also called semi-enriched) metal dissolution liquid from the reactor outlet 450 and supplies it back into the reactor at its inlet 440. The loop 460 is formed by the reactor outlet 450, the recirculation tank 420, a recirculation tank outlet 470 connected to the reactor inlet 440, and the reactor inlet 440. The system 400 includes a second metal dissolution liquid recirculation loop 461 that takes a semi-loaded metal dissolution liquid from the reactor outlet 450 and supplies it back into the reactor at its inlet 440. The loop 461 is formed by the reactor outlet 450, the recirculation tank 430, a recirculation tank outlet 471 connected to the reactor inlet 440, and the reactor inlet 440. The reactor inlet 440 also receives a new metal dissolution liquid having an acidity expected to be higher than that of the recirculating semi-loaded metal dissolution liquid (or also referred to as "reagent feed" in FIGS. 6A-6E). The new metal dissolution liquid and the semi-loaded metal dissolution liquid may be mixed before being supplied into the reactor 410 through the inlet 440.

[0062] The systems described herein, such as the system shown in FIGS. 6A-6E, may be operated under batch processing conditions. In an embodiment, the metal dissolution batch process includes circulating a first metal dissolution liquid through a first recirculation loop having a first recirculation tank in fluid communication with a metal dissolution apparatus containing a metal-containing material, dissolving metal from the metal-containing material into the first metal dissolution liquid to form a first loaded metal dissolution liquid, and flowing the first loaded metal dissolution liquid downstream from the first recirculation tank. The process further includes circulating a second metal dissolution liquid through a second recirculation loop having a second recirculation tank in fluid communication with the metal dissolution apparatus containing the metal-containing material, dissolving metal from the metal-containing material into the second metal dissolution liquid to form a second loaded metal dissolution liquid, and flowing the second loaded metal dissolution liquid downstream from the second recirculation tank. The process further includes flowing the first loaded metal dissolution liquid downstream while circulating the second metal dissolution liquid through the second recirculation loop. The process further includes flowing the second loaded metal dissolution liquid downstream while circulating the first metal dissolution liquid through the first recirculation loop.

[0063] The first or second metal dissolution liquid may be circulated through the apparatus with substantially spatial uniformity. The first or second metal dissolution liquid may be circulated through the apparatus with substantially spatial uniformity under a relatively low hydrostatic pressure load while maintaining a substantially uniform metal dissolution state over the length, width, and height of the apparatus. The first or second metal dissolution liquid may be supplied into the apparatus through a plurality of porous pipes to more evenly disperse the solution throughout the apparatus. The metal dissolution state may include pH, ratio of leaching reagent, temperature, dissolved metal concentration, or combinations thereof.

[0064] The process may include dissolving metal from a metal-containing substance into a first or second metal dissolution solution that circulates. The first or second metal dissolution solution may be circulated into the apparatus at a first location and out of the apparatus at a second location. The first location may be positioned at the lower part of the apparatus, and the second location may be positioned at the upper part of the apparatus. The process includes circulating the first metal dissolution solution through a first recirculation loop and separately circulating the second metal dissolution solution through a second recirculation loop. The first recirculation loop may include circulating the first metal dissolution solution from a reactor at the second location to a first recirculation tank and from the first recirculation tank to the reactor at the first location. The second recirculation loop may include circulating the second metal dissolution solution from a reactor at the second location to a second recirculation tank and from the second recirculation tank to the reactor at the first location. The process may further include supplying a metal dissolution reagent into the first or second metal dissolution solution when the solution circulates from the first or second recirculation tank to the reactor at the first location. The process may further include circulating the first or second metal dissolution solution through the first or second recirculation loop, increasing the concentration of the dissolved or leached metal, and forming a first or second loaded metal dissolution solution. The first or second loaded metal dissolution solution contains dissolved or leached metal at a specific or desired concentration. Once the first or second loaded metal dissolution solution is formed, the batch process is complete. The process subsequently includes flowing the first or second loaded metal dissolution solution from the first or second recirculation tank for further processing downstream. The process includes flowing the first loaded metal dissolution solution downstream while circulating the second metal dissolution solution through the second recirculation loop. The process further includes flowing the second loaded metal dissolution solution downstream while circulating the first metal dissolution solution through the first recirculation loop.

[0065] In an embodiment, the metal dissolution system 400 shown in FIGS. 6A-6E is operated under batch process conditions, where the metal dissolution solution may be prepared from a reagent containing sulfuric acid and hydrogen peroxide, and the process temperature may be below the decomposition temperature of hydrogen peroxide (generally considered <85° C.).

[0066] The process includes feeding a metal-containing substance (metal feed) into reactor 410 through the upper part 480 of reactor 410 and filling the first recirculation tank 420 with water (FIG. 6A). The water is then circulated through system 400 using a first recirculation loop 460 through which fresh metal dissolution solution is fed into the first recirculation loop 460 in front of the reactor inlet 440, and the fresh metal dissolution solution is formed from fresh acid and optionally an oxidizing agent added from the first recirculation tank 420 into the water / half-loaded metal dissolution solution (FIG. 6B). Over time, as the fresh / half-loaded metal dissolution solution circulates through reactor 410, the concentration of dissolved or leached metal (e.g., in the form of metal ions) in the recirculating solution increases. In parallel, the second recirculation tank 430 may be filled with water.

[0067] Once the recirculating solution reaches a desired dissolved or leached metal concentration, the first loaded metal dissolution solution is considered formed. The recirculation then changes direction from the first recirculation loop 460 to the second recirculation loop 461, where the water from the second recirculation tank 430 is circulated through system 400 using the second recirculation loop 461 with fresh metal dissolution solution added thereto. In parallel, the first loaded metal dissolution solution from the recirculation tank 420 is sent downstream for further processing (FIG. 6C). Once the first recirculation tank 420 is emptied, the entire leaching process repeats itself (FIGS. 6A - 6D). In parallel, the second loaded metal dissolution solution from the second recirculation tank 430 is sent downstream for further processing (FIG. 6E). In both systems and processes of 300 and 400, the recirculation of the semi-enriched leachate helps to dilute the acidity of the fresh leachate before the reactor and also helps in mass transport, promoting the dissolution of metal as a larger volume of solution passes through the layer of metal in the reactor.

[0068] Embodiments of the present disclosure are metal dissolution batch processes that include recirculating all of the semi-rich leachate through the reactor and, simultaneously, adding fresh leachate to the reactor to aid in leaching metal from the metal-containing material within the reactor by admixture. The fresh leachate and the recirculated semi-rich leachate may be admixed prior to being fed into the reactor. Recirculation of the semi-rich leachate may be stopped in response to the amount of metal dissolved in the semi-rich leachate reaching a threshold amount to form a rich leachate. The rich leachate may be discharged downstream. While the rich leachate is being discharged downstream, addition of fresh leachate to the reactor may be stopped.

[0069] The rich leachate from the reactor may be admixed / mixed with the rich leachate(s) of one or more other reactors to form a final rich leachate having a desired level of dissolved metal therein. Using a number of the batch metal dissolution processes described herein and mixing the rich leachates resulting from these individual batch processes in specific amounts may allow for better control of the final amount of dissolved metal sent downstream. Further, this admixture of the PLS may allow a wider variety of metal-containing materials to be collectively processed by the reactor(s) by eliminating the need to pre-mix the metal-containing materials prior to feeding them into the reactor(s). The types and amounts of metals in the metal-containing materials fed into the reactor can vary significantly over time.

[0070] Systems and methods for controlling the metal dissolution apparatuses described herein may include one or more of the following considerations or constraints. Systems and methods for controlling the apparatuses described in FIGS. 5A-5D and FIGS. 6A-6D may include one or more of the following considerations and / or constraints, where the metal-containing material comprises nickel and the metal dissolution solution comprises sulfuric acid and an optional oxidizing agent in water. - The nickel concentration may be selected based on the ratio of the flow rates of sulfuric acid and water in the added reagent by adjustment of dilution with other reagents. - When an oxidizing agent is used, the flow of the oxidizing agent is proportioned relative to the flow of the acid, and this ratio can be kept within a relatively strict numerical range to avoid an oxidizing potential that is too high, which may cause metal passivation in some systems, or too low, which may cause loss of the oxidizing agent, as well as an oxidizing potential that is too low and may reduce the reaction rate and the degree of reaction progress. - The control system may be configured to be a pull or push system. In the case of a pull system, the solution of the desired flow rate (e.g., nickel-loaded metal dissolution solution) may be drawn from the recirculation tank and flushed to the next processing stage. In this case, the flow of the incoming metal dissolution solution may be adjusted to control the level of the recirculation tank. In the case of a push system, the flow of the metal dissolution solution may be set to provide the mass flow rate required for metal dissolution at the required concentration, and the level of the recirculation tank may be controlled by the controller to flow out of the system to the next stage of the process. - The metal dissolution rate may increase with the flow rate of the solution through the reactor. The flow through the reactor may be set independently of the flow of the reagent. - In a system with a specific oxidizing agent, the degree of reaction progress is generally independent of the exact amount of metal in the dissolver because the oxidizing agent is instantaneous. Similar dissolution behavior can be expected as long as the dissolver can be maintained to be about 80 - 100% full of metal.

[0071] The apparatuses or systems described herein, such as those described in FIGS. 5A-5D and FIGS. 6A-6D, may comprise equipment for measuring the combination of temperature, metal concentration, residual acid, and (if any) residual oxidant at the solution outlet of the reactor. Spectroscopic measurement, colorimetric measurement, solution concentration, pH measurement, or ORP measurement may, for example, serve as indicators for determining metal concentration, acidity, and residual oxidant within a particular system. The apparatuses or systems described herein, such as those described in FIGS. 5A-5D and FIGS. 6A-6D, may comprise equipment useful for detecting impurities, including impurities that may be harmful to downstream processing. In an embodiment, the equipment useful for detecting impurities may be configured to measure the solution exiting the metal dissolution apparatus or the recirculation tank. Impurity measurement may be used to control the supply of metal-containing substances into the metal dissolution apparatus. Such control may include retarding or halting the supply of a particular metal-containing substance into the apparatus in response to a threshold impurity level detected by the equipment.

[0072] The use of such equipment and corresponding measurements may enable control such that the apparatuses or systems described herein affect the effluent solution composition and / or serve to avoid large recirculation tanks. Examples of methods (including select parameters) for controlling the apparatuses / reactors described herein using the above-described measurements with a “pull” control strategy are outlined in the table below. Similar methods exist for “push”-based control strategies.

Table 1

[0073] The above control methods are merely representative examples. In an instrument system, an automated control system may be implemented to keep the composition of the stream from this system within strict bounds as it moves to the next processing stage.

[0074] Metallic copper can be formed in the reactor. This can be formed, for example, as precipitated copper on nickel powder. The formation of metallic copper in the reactor is not preferred. High levels of pH (insufficient acid) and / or low levels of peroxide within the reactor or at a particular location in the reactor may cause the formation of metallic copper.

[0075] In a conventional column reactor, for example, metallic copper is more likely to occur in the solution discharge area and / or the upper area of the column (e.g., when the column is operating in countercurrent mode) where the pH is highest (lowest acidity) and / or the peroxide is lowest, or in the vicinity thereof. This is due to the vertical gradient of pH / peroxide across the reactor. As the metal dissolution solution having a high acidity and / or a high peroxide level passes through the column reactor and into the discharge box / upper area, the acidity of the solution and / or the amount of peroxide in the solution decreases due to the dissolution of the metal-containing substances between them. The higher the column, the greater the pH / peroxide gradient across the reactor and the greater the risk of metallic copper formation.

[0076] In embodiments, reactors and / or apparatuses having a height that is less than their length can result in more uniform processing conditions across the reactor(s) / apparatus, such as pH level and peroxide level, and can help to suppress the formation of metallic copper. Compared to conventional column reactors, the lower height of the reactors of the present disclosure can result in an increase in the concentration of oxidant exiting the reactor (e.g., at the top of the reactor) such that the metal within the reactor is exposed to a more uniform oxidant concentration profile across the overall height of the reactor. This uniform exposure reduces the likelihood of insufficient oxidant levels in certain areas of the reactor that would otherwise allow for the formation of metallic copper from the leachate in these areas. In embodiments of the present disclosure, the operating conditions of target areas / zones (such as upper areas / zones of the reactor) that may be prone to forming metallic copper are manipulated to cause solubilization of nickel powder (onto which copper can cement) and / or to create other situations that are unfavorable for copper cementation. The copper-containing solution may then be processed in a secondary reactor (e.g., a box reactor according to the present disclosure that may be smaller than the main reactor) specialized for copper removal by creating conditions favorable for forming metallic copper and separating it from the solution.

[0077] In other embodiments, copper in the solution emerging from the reactor is separated by downstream processing such as ion exchange and / or neutralization, and / or other separation methods.

[0078] In embodiments, the redox potential solution and / or pH may be selected to help suppress copper cementation within the reactor. The copper may subsequently be captured downstream of the reactor. The copper may be captured downstream by one or more reactors.

[0079] In an embodiment, the formation of metallic copper in the reactor may be suppressed by intermittently or continuously changing the operating conditions of the reactor. In an embodiment of changing the operating conditions, the pH level in the reactor may be lowered where the solution is supplied into the reactor. A replenishment solution of lower pH may be supplied into the reactor at any location of the reactor along the path of the solution through the reactor. The replenishment solution may contain an oxidizing agent. These operating conditions may vary in a specific area of the reactor, such as an area where the solution is discharged from the reactor which may be an upper zone or a reactor operating in a countercurrent mode.

Claims

1. A metal dissolution apparatus, comprising: a reactor; a metal inlet at a first position for supplying a metal-containing substance into the reactor; a solution inlet at a second position for supplying a metal dissolution solution into the reactor; a solution outlet at a third position for discharging the metal dissolution solution from the reactor; a ventilation opening at a fourth position; and the apparatus has a length and a height, and the height is less than the length, the metal dissolution apparatus.

2. The apparatus according to claim 1, wherein the apparatus is the reactor.

3. The metal dissolution apparatus according to claim 1, wherein the apparatus comprises a plurality of reactors.

4. Each of the plurality of reactors has a length and a height, wherein the height is less than the length, or wherein the height is longer than the length, the metal dissolution apparatus according to claim 3.

5. The metal dissolution apparatus according to any one of claims 1 to 4, further comprising a dividing portion that defines a plurality of reactors within the apparatus.

6. The metal dissolution apparatus according to any one of claims 1 to 5, further comprising a reactant dispersion device provided within the apparatus for receiving the solution and dispersing the solution with substantially spatial uniformity across the reactor.

7. The apparatus according to claim 1, further comprising a transport system connected to the apparatus for supplying the metal-containing substance to the metal inlet.

8. The apparatus according to claim 1 or 7, wherein the ratio of height to width is less than 1.

9. The apparatus according to claim 1 or 8, wherein the apparatus is self-standing.

10. The apparatus according to any one of claims 1 to 9, wherein the reactor is configured to fit within a standard transport container such as a transport container having dimensions of approximately 4×4×12 m.

11. The apparatus according to any one of claims 1 to 10, wherein the reactor has a substantially rectangular shape.

12. The apparatus according to any one of claims 1 to 11, wherein the reactor is modular.

13. The apparatus according to any one of claims 1 to 6, wherein the metal inlet is at a first position along the upper part of the reactor.

14. The solution inlet is at a second position along the height and length of the reactor, and optionally extends along the length of the reactor, or The apparatus according to any one of claims 1 to 13, wherein the solution inlet is at a second position along the height and width of the reactor and optionally extends along the width of the reactor.

15. The solution outlet is at a third position along the height and length of the reactor and optionally extends along the length of the reactor, or The solution outlet is at a third position along the height and width of the reactor and optionally extends along the width of the reactor. The apparatus according to any one of claims 1 to 14.

16. When along the length of the reactor, the solution inlet is within the lower part of the reactor and the solution outlet is within the upper part of the reactor to supply a flow of solution countercurrent to the flow of the metal-containing substance. The apparatus according to any one of claims 1 to 15.

17. When along the length of the reactor, the solution inlet is within the upper part of the reactor and the solution outlet is within the lower part of the reactor to supply a flow of solution cocurrent to the flow of the metal-containing substance. The apparatus according to any one of claims 1 to 16.

18. When along the width of the reactor, the solution inlet is at one end of the reactor and the solution outlet is at the opposite end of the reactor to supply a flow of solution flowing across the flow of the metal-containing substance. The apparatus according to any one of claims 1 to 17.

19. The solution inlet comprises a series of inlets extending along the outer length of the reactor connected to a series of porous pipes extending across the inner width of the reactor for dispersing the metal leaching solution with substantially spatial uniformity throughout the reactor. The apparatus according to any one of claims 1 to 18.

20. The solution inlet comprises a tapered manifold. The apparatus according to any one of claims 1 to 19.

21. The ventilation system comprises a gas outlet for providing a gas flowing out of the reactor and optionally further comprises a gas inlet for providing a gas flowing into the reactor and optionally further comprises a gas capture system. The apparatus according to any one of claims 1 to 20.

22. The reactant dispersion device according to any one of claims 6 to 21, comprising a porous pipe provided in the device for receiving the solution from the inlet and dispersing the solution with substantially spatial uniformity across the reactor.

23. Supplying a metal dissolution solution to a first position of a metal dissolution device containing a metal-containing substance with substantially spatial uniformity, Flowing the metal dissolution solution through the device under a relatively low hydrostatic pressure load while maintaining a substantially uniform metal dissolution state across the length, width, and height of the device, Dissolving metal from the metal-containing substance into the metal dissolution solution, A metal dissolution treatment method of discharging the metal dissolution solution from a second position of the device.

24. The metal dissolution treatment method according to claim 24, wherein the first position is at the lower part of the device and the second position is at the upper part of the device.

25. The treatment method according to claim 23, wherein the treatment is a continuous treatment or a batch treatment.

26. The treatment method according to any one of claims 23 to 25, wherein the solution is supplied into the device through a plurality of porous pipes so that the solution is more uniformly dispersed across the device.

27. The treatment method according to any one of claims 23 to 26, wherein the metal dissolution solution is recycled or reused, or a part of the solution is recycled or reused.

28. The treatment method according to any one of claims 23 to 27, wherein the metal dissolution state includes pH, ratio of leaching reagent, temperature, dissolved metal concentration, or a combination thereof.

29. The treatment method according to any one of claims 23 to 28, wherein the device comprises a rectangular reactor with a height shorter than its length.

30. The treatment method according to any one of claims 23 to 29, wherein the solution is supplied into a reactant dispersion device in the device so that the solution is more uniformly dispersed across the device.

31. Use of a metal dissolution device with a height shorter than its length for dissolving metal from a metal-containing substance.

32. Supplying a metal-containing substance into a reactor, Receiving and mixing a fresh metal dissolution solution and a second solution containing an amount of dissolved metal less than a threshold amount therein to form a third solution that is a metal dissolution solution. The step of supplying the third solution into the reactor, and the step of dissolving metal from the metal-containing substance to form a semi-loaded solution, The step of supplying all of the semi-loaded solution into the reactor as the second solution of the third solution, a metal dissolution treatment method.

33. The metal dissolution treatment method according to claim 32, wherein the second solution is initially water.

34. The step of supplying water into a recirculation tank, The step of supplying the second solution from the recirculation tank, further included in the metal dissolution treatment method according to claim 32 or 33.

35. The method further includes the step of recirculating all of the semi-loaded solution through the reactor as the second solution of the third solution until the semi-loaded solution contains a target threshold amount of dissolved metal therein to form an enriched leachate.

36. The metal dissolution treatment method according to any one of claims 32 to 35, further including the step of stopping receiving the new metal dissolution solution according to the step of the semi-loaded solution forming the enriched leachate.

37. The metal dissolution treatment method according to any one of claims 32 to 36, further including the step of supplying the enriched leachate downstream.

38. The step of supplying the enriched leachate downstream according to claim 37 includes the step of supplying the enriched leachate to a buffer tank.

39. The metal dissolution treatment method according to claim 37, further including the step of receiving water from a second recirculation tank after all of the enriched leachate has been supplied downstream.

40. The metal dissolution treatment method according to any one of claims 32 to 39, further including the step of mixing the enriched leachate of the treatment with the enriched leachate(s) of one or more other metal dissolution treatments to form a fourth solution having a desired level of dissolved metal therein.

41. A reactor, A metal inlet at a first position of the reactor for receiving a metal-containing substance, A solution inlet at a second position of the reactor for receiving a metal dissolution solution, A solution outlet at a third position of the reactor for discharging the metal dissolution solution in which dissolved metal is dissolved from the reactor, A metal dissolution apparatus comprising a recirculation loop having a recirculation tank connecting a solution outlet for supplying all of the metal dissolution solution from the solution outlet to the solution inlet to the solution inlet.

42. The metal dissolution apparatus according to claim 41, further comprising a valve for supplying and returning all of the contents of the recirculation tank to the solution inlet.

43. Further comprising a buffer tank connected to the recirculation tank via the valve, The metal dissolution apparatus according to claim 42, wherein the valve suppresses the metal dissolution solution from moving from the recirculation tank to the buffer tank until the metal dissolution solution contains a threshold amount of dissolved metal therein.

44. Further comprising a copper handling reactor in fluid communication with the one or more reactors for receiving the enriched leachate from the reactor, The copper handling reactor is for cementing copper in the reactor from the enriched leachate, and the metal dissolution apparatus according to any one of claims 1 to 29.

45. The metal dissolution treatment method according to any one of claims 32 to 40, further comprising the step of suppressing the formation of metallic copper in the area of the one or more reactors by changing the operating conditions of the reactor(s).

46. The metal dissolution treatment method according to claim 45, wherein changing the operating conditions includes lowering the pH level in one or more of the reactors or a specific area (s) thereof.

47. The metal dissolution treatment method according to claim 45, wherein changing the operating conditions includes causing different oxidation potentials in one or more of the reactors in that specific area (s).

48. The metal dissolution treatment method according to claim 46, wherein lowering the pH includes supplying additional acid into the one or more reactors.

49. The metal dissolution treatment method according to claim 47, wherein causing the different oxidation potentials includes supplying additional oxidizing agent into the one or more reactors.

50. The additional acid or the additional oxidizing agent is supplied into the one or more reactors via the third solution, and the metal dissolution treatment method according to claim 48 or 49.

51. The additional acid or the additional oxidizing agent is supplied into the one or more reactors as a replenishing solution at a replenishing position different from the position where the third solution is supplied into the reactor(s), according to the metal dissolution treatment method of claim 48 or 49.

52. The replenishing solution is formed by receiving a semi-load solution from the one or more reactors and supplying the additional acid and / or the additional oxidizing agent thereto, according to the metal dissolution treatment method of claim 51.

53. The semi-load solution is received from an intermediate withdrawal position of the one or more reactors that can be a position between the position for supplying the third solution into the reactor(s) and the position for withdrawing the semi-load solution or the enriched leachate from the reactor(s), according to the metal dissolution treatment method of claim 52.

54. The replenishing solution is supplied to a position close to the position of the reactor(s) from which the semi-load solution or the enriched leachate is withdrawn from the reactor(s), according to the metal dissolution treatment method of claim 51 or 52.

55. The replenishing position is an upper zone(s) of the reactor(s), according to the metal dissolution treatment method of claim 51 or 52.

56. The metal dissolution treatment method according to any one of claims 32 to 55, further comprising the step of capturing and / or separating copper from the enriched leachate.

57. The metal dissolution treatment method according to claim 56, further comprising the step of receiving the enriched leachate in a downstream reactor and the step of cementing metallic copper from the enriched leachate in the downstream reactor.

58. The metal dissolution treatment method according to claim 57, further comprising the step of separating the copper from the enriched leachate downstream of the reactor(s) using ion exchange, neutralization, or other separation methods.

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