Calcium Chloride Agglomeration for Copper Leaching Efficiency
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Solution Overview
Problem
Current copper leaching processes are inefficient for primary minerals like chalcopyrite and bornite, as they rely on bioleaching or chemical leaching with modest results, and lack the use of recirculated solutions and elevated temperatures to enhance copper extraction.
Innovation Solution
The process involves adding calcium chloride during agglomeration, using a recirculated solution with elevated temperatures in the curing and leaching stages, and heating the mineral or solutions to improve copper extraction, particularly for primary and secondary copper minerals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional chemical leaching is used for primary copper minerals, then the process is simpler to operate, but copper extraction efficiency is low
Solution Approach 1:
The patent applies preliminary action by adding calcium chloride during the agglomeration stage before leaching begins. This pre-treatment modifies the mineral structure and creates favorable conditions for subsequent leaching, enabling more efficient copper extraction from primary minerals without requiring complex additional equipment
Solution Approach 2:
The patent changes chemical parameters by introducing calcium chloride to alter the leaching environment. This addition modifies the chemical composition and reactivity of the system, transforming the leaching mechanism to enable efficient extraction of primary copper minerals through enhanced chemical reactions
2Productivity
If calcium chloride is added during agglomeration, then copper extraction efficiency improves, but the process complexity increases
Solution Approach 1:
The patent merges the agglomeration and chemical modification steps by adding calcium chloride during agglomeration. This integration allows the binding and chemical activation to occur simultaneously in one process stage, improving copper recovery while avoiding the need for separate treatment steps
Solution Approach 2:
The calcium chloride addition serves multiple functions: it acts as a binding agent during agglomeration, provides chloride ions for leaching reactions, and modifies the mineral structure to enhance copper extraction. This multi-functionality improves productivity without proportionally increasing process complexity
3Speed
If recirculated solution is used in agglomeration, then leaching speed increases, but solution management complexity increases
Solution Approach 1:
The patent implements continuous action by recirculating the leaching solution back to the agglomeration stage. This creates a closed-loop system where the solution continuously acts on the mineral material, maintaining high leaching speed through persistent chemical contact without requiring additional processing stages
4Productivity
If elevated temperature is applied in curing and leaching, then copper extraction efficiency improves, but energy consumption increases
Solution Approach 1:
The patent applies parameter changes by elevating the temperature in the curing and leaching stages. This thermal parameter modification accelerates the chemical reactions and increases copper extraction efficiency, with the energy input justified by the significant improvement in extraction rates
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly enhances copper recovery by regenerating ferric ions, stabilizing cuprous ions, and increasing leaching speed, achieving higher copper extraction rates and efficiency compared to traditional methods.
Implementation Method 1
CaCl2+H2SO4+2H2O=CaSO4*2H2O+2H++2Cl−
Implementation Method 2
Mineral+H2SO4=Fe3++H2O+SO42−
Implementation Method 3
CuO+H2SO4=Cu2++SO42−+H2O
Implementation Method 4
Cu2S+2Fe3+=Cu2++CuS+2Fe2+
Implementation Method 5
CuS+2Fe3+=Cu2++2Fe2++S
Implementation Method 6
Cu+2+Fe2+=Cu++Fe3+
Implementation Method 7
2Cu++1⁄2O2+2H+=2Cu2++H2O
Data Source
AI summary
A process to significantly improve the copper chemical leaching process for primary and secondary minerals, using calcium chloride including the agglomeration, curing, and leaching with a high content of chloride, iron and copper stages. The mineral is then washed with a low concentration of copper and a high concentration of acid, where the impregnated copper is extracted from the pit and wherein a recirculated solution is used in the agglomeration stage.