Copper Recovery from Dilute Mining Water via Electrodeposition-Redox Replacement
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Solution Overview
Problem
Current methods for recovering copper from dilute copper-iron bearing mining waters are economically unfeasible and energy-intensive, especially when copper is present at low concentrations, and existing electrochemical processes do not effectively utilize the iron impurity as a reducing agent for copper recovery.
Innovation Solution
The electrodeposition-redox replacement method (EDRR) is employed, where iron from the mining water acts as a reducing agent after being deposited on an electrode, allowing for repeated cycling between electrodeposition and redox replacement steps to recover copper with lower energy consumption without additional chemical consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional electrowinning is used to recover copper from dilute mining waters, then copper recovery is achieved, but energy consumption is excessively high and the process is economically unfeasible
Solution Approach 1:
The invention converts the harmful iron impurity in dilute mining waters into a beneficial reducing agent. Iron is first electrodeposited onto the cathode, then spontaneously reduces copper ions from the solution through redox replacement, eliminating the need for continuous high-energy external current application and dramatically reducing energy consumption while effectively recovering copper even at low concentrations
Solution Approach 2:
The invention employs periodic cycling between electrodeposition phase (applying external current to deposit iron) and redox replacement phase (allowing spontaneous copper deposition). This periodic action allows the system to accumulate iron on the cathode, then utilize it for copper recovery, creating an efficient cyclic process that overcomes the limitations of continuous electrowinning
2Reliability
If electrodeposition is applied to recover copper from dilute solutions, then copper can be deposited, but the process becomes economically unfeasible due to high energy requirements
Solution Approach 1:
The system achieves self-service by using the electrodeposited iron itself as the reducing agent for copper recovery. The iron on the cathode spontaneously reduces copper ions without requiring additional external energy input, making the process self-sustaining during the redox replacement phase and dramatically reducing overall energy consumption while maintaining reliable copper deposition
3Ease of manufacture
If traditional cementation process is used, then copper can be precipitated, but additional metal powder must be added in excess, increasing cost and waste
Solution Approach 1:
The invention uses the electrodeposited iron layer on the cathode as an intermediary reducing agent. This iron intermediary spontaneously transfers electrons to copper ions in solution through redox replacement, enabling copper precipitation without requiring addition of external metal powder. The iron is obtained in-situ from the mining water itself, eliminating the need for external metal powder addition and associated costs
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 method enables the recovery of copper from dilute solutions with low energy consumption, achieving high purity copper recovery even at low concentrations, and is more efficient than traditional electrowinning, particularly when the iron-to-copper ratio is high, reducing waste formation and operating expenses.
Implementation Method 1
an electrodeposition (ED) step, wherein an external potential or current is applied to an electrode placed in the dilute copper and iron bearing solution, depositing iron and optionally copper on the electrode
Implementation Method 2
a redox replacement (RR) step, wherein the applied external potential or current used in step a) is cut-off and iron deposited on the electrode reduces spontaneously the copper still present in the solution
Data Source
AI summary
The invention relates to a method of removing and/or recovering metals from a dilute metal containing solution. In particular, the invention concerns a method for recovering copper from a dilute copper-iron bearing mining water, particularly from a copper-iron bearing mining wastewater.