Carbon Catalyst Leaching of Copper Arsenic Sulfosalt
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Solution Overview
Problem
Current methods for recovering copper from copper arsenic sulfosalt and copper antimony sulfosalt minerals are inefficient and economically unviable, with bioleaching being slow and chemical leaching achieving incomplete recoveries, while processes like total pressure oxidation are not economically feasible.
Innovation Solution
A hydrometallurgical chemical leaching process using carbon as a catalyst in an acidic sulfate leach solution with an oxygen-containing gas to extract copper from copper concentrates, maintaining specific carbon-to-copper sulfide ratios and operating potentials to enhance copper recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bioleaching is used to recover copper from copper arsenic sulfosalt and copper antimony sulfosalt minerals, then copper can be extracted, but the process is very slow and achieves incomplete recoveries even after many weeks to months
Solution Approach 1:
The patent changes the chemical parameters of the leaching system by introducing a carbon catalyst and adjusting the redox potential to at least 390 mV versus Ag/AgCl. This parameter change transforms the slow bioleaching process into a rapid chemical leaching process that achieves complete copper recovery in a fraction of the time, directly resolving the contradiction between extraction rate and time required.
Solution Approach 2:
The patent introduces carbon as a catalyst that acts as an intermediary substance to facilitate the leaching reaction. The carbon catalyst mediates the interaction between the leach solution and copper sulfide minerals, enabling rapid copper dissolution without requiring lengthy bioleaching periods, thus resolving the time-productivity contradiction.
2Productivity
If total pressure oxidation in autoclaves with oxygen at temperatures exceeding 200° C. is used to leach enargite, then copper can be recovered, but the process is not economically viable
Solution Approach 1:
The patent changes the temperature parameter from exceeding 200° C. to below 200° C. (specifically maintaining temperatures that prevent significant pyrite oxidation while achieving copper leaching). This parameter change maintains complete copper recovery while dramatically reducing energy costs and equipment requirements, thereby improving economic viability.
Solution Approach 2:
The patent replaces the expensive autoclave system with simpler, less costly equipment that operates at lower temperatures and pressures. The process uses inexpensive carbon catalyst and standard leaching tanks, eliminating the need for costly pressure vessels and high-temperature infrastructure, thus resolving the economic viability issue.
3Productivity
If enargite-containing copper concentrates are submitted to smelters for toll treatment, then copper can be processed, but heavy financial penalties are incurred due to high arsenic levels
Solution Approach 1:
The patent extracts copper from the concentrate through selective chemical leaching, separating it from arsenic and other unwanted elements. The leach solution selectively dissolves copper while leaving arsenic in the solid residue, which can then be discarded. This extraction process eliminates the need for smelting and associated arsenic penalties while maintaining complete copper recovery.
Solution Approach 2:
The patent converts the presence of arsenic-containing minerals from a harmful factor into a benefit by using the carbon-catalyzed leaching process to selectively extract copper while leaving arsenic behind. The arsenic-bearing residue becomes an easily disposable waste stream rather than a penalty-incuring feed material, transforming the harmful aspect into a process advantage.
4Productivity
If chemical leaching without carbon catalyst is used on copper arsenic sulfosalt and copper antimony sulfosalt minerals, then copper can be leached, but recoveries are incomplete
Solution Approach 1:
The patent introduces carbon as a catalyst that acts as an intermediary to facilitate complete copper dissolution. The carbon surface provides active sites that enhance the chemical reaction between the leach solution and copper sulfide minerals, enabling complete recovery rather than the incomplete recoveries achieved without the catalyst.
Solution Approach 2:
The patent changes the redox potential parameter to at least 390 mV versus Ag/AgCl and introduces carbon catalyst, which fundamentally alters the leaching mechanism. These parameter changes transform the incomplete chemical leaching process into one that achieves complete copper recovery, resolving the contradiction between extraction capability and recovery completeness.
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
The process achieves rapid and complete copper extraction from copper arsenic and antimony sulfosalt minerals, with over 99% copper recovery in 22 hours, using recycled carbon and optimized operating conditions, making it economically viable.
Implementation Method 1
a hydrometallurgical chemical leaching process which uses carbon as a catalyst for the leaching reaction
Implementation Method 2
Copper is chemically leached from the concentrate in the leach solution in the presence of an oxygen-containing gas to produce a solution containing copper ions
Data Source
AI summary
A method of recovering copper from a copper sulfide concentrate comprising a copper arsenic sulfosalt or a copper antimony sulfosalt, using carbon as a catalyst. The concentrate and carbon are added to an acidic sulfate leach solution. The copper is leached from the concentrate, in the presence of an oxygen-containing gas. The operating potential is maintained above a selected level. The carbon copper sulfide ratio of the carbon being added to the copper sulfide present in the concentrate being added is at least 1:20. The carbon may be maintained above a selected concentration in the leach solution. The leached copper is recovered from the solution by conventional methods.