Dissolved Air Flotation in Solvent Extraction Filter Vessel
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Solution Overview
Problem
Existing solvent extraction/electrolyte filter systems, combining air floatation and coalescing processes, are inefficient at high flow rates, leading to reduced copper quality and frequent shutdowns, with costly and resource-intensive equipment and maintenance needs.
Innovation Solution
A system using a dissolved air floatation pump to introduce high-pressure air into an electrolyte solution within a pressurized SX filter vessel, combined with coalescing media, where the downward solution flow matches the upward bubble flow, enhancing organic molecule removal efficiency without a separate floatation column.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate floatation column is used before the filter, then organic molecule removal efficiency is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the floatation function and filtration function into a single integrated filter vessel. Dissolved air floatation is performed within the filter vessel itself, eliminating the need for a separate floatation column. The pump introduces dissolved air into the solution in the feed inlet line, and bubbles rise through the coalescing media in the filter vessel, achieving both floatation and filtration in one unit.
Solution Approach 2:
The filter vessel is designed to perform multiple functions: it serves as both the filtration unit with coalescing media and the floatation unit with dissolved air injection. This multi-functional design eliminates the need for separate equipment while maintaining the effectiveness of both processes.
2Productivity
If feed flow rate is increased to boost productivity, then copper production rate is improved, but organic molecule removal efficiency deteriorates
Solution Approach 1:
The system maintains continuous effective separation by ensuring that dissolved air bubbles continuously rise through the coalescing media at a rate that matches the downward solution flow. This continuous action ensures that organic molecules are consistently removed regardless of the feed flow rate, allowing high productivity without sacrificing removal efficiency.
Solution Approach 2:
The patent changes the physical state of air from gaseous to dissolved state by pressurizing it, then introduces it into the solution at a pressure greater than the internal pressure of the filter vessel. This parameter change allows the air to be introduced in a controlled manner that maintains effectiveness across varying flow rates.
3Manufacturing precision
If high-pressure air is introduced into the solution, then bubble generation and floatation efficiency are improved, but energy consumption increases
Solution Approach 1:
The system uses the pressure differential between the high-pressure dissolved air source and the filter vessel internal pressure to drive the air dissolution and injection process. The pump introduces dissolved air at a pressure substantially greater than the internal pressure of the filter vessel, allowing the pressure difference to facilitate the process without requiring additional energy-intensive components.
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 system achieves a 98.5% removal efficiency of organic molecules, allowing for higher copper production rates and grades, reduced downtime, and lower capital and operational costs, with easier modification of existing systems.
Implementation Method 1
a pump adapted to introduce dissolved air into the solution in the feed inlet line
Implementation Method 2
dissolved air is first introduced into the solution so that it adheres to the organic molecules in the system, which molecules are thereby raised as the air floats to the top
Implementation Method 3
The introduced air bubbles adhere to some of the organic molecules which are, as a result, caused to float to the top of the system
Data Source
Figure 1
Figure 2~3
AI summary
A system for filtering organic molecules from an electrolyte solution, including a feed inlet line adapted to carry a solution with organic molecules, a filter vessel secured to the inlet line, and a pump adapted to introduce dissolved air into the solution in the feed inlet line. The filter vessel is a solvent extraction filter having coalescing media above a solution outlet at the bottom of the vessel and an organic vent outlet at the top of the vessel. The system operates by (a) dissolving air into the solution, (b) inputting the solution with dissolved air into the filter vessel, (c) outletting solution from the bottom vessel outlet to flow solution down through coalescing media, and (d) periodically venting floating organic molecules from the top of the vessel.