Multi-Compartment Electrolytic Cell for Copper Recovery
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Solution Overview
Problem
Existing methods for removing heavy metal ions from liquid streams are inefficient, costly, and generate toxic byproducts, particularly in low-concentration solutions, and fail to effectively utilize 'waste' ores and contaminated sites for copper recovery.
Innovation Solution
An electrolytic cell system with multiple compartments and selective ion conductive membranes that allows for the concentration of desired ions through unidirectional electric current, enabling the economic recovery of copper from low-grade ores and contaminated sites by separating and transferring ions into a central compartment for further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chemical precipitation methods are used to remove heavy metal ions, then removal efficiency is improved, but device complexity and cost increase significantly
Solution Approach 1:
The electrolytic cell is divided into multiple compartments (anode compartment, cathode compartment, and intermediate compartment) separated by ion-conductive membranes. This segmentation allows selective ion transport and concentration in specific zones, enabling efficient heavy metal removal while simplifying the overall process compared to complex chemical precipitation systems.
Solution Approach 2:
Ion-conductive membranes serve as intermediaries between the anode and cathode compartments, facilitating selective ion transport. These membranes enable controlled migration of metal ions during electrolysis, achieving efficient removal without requiring complex chemical reagents or multiple processing steps.
2Productivity
If conventional electrowinning technology is used, then copper recovery is achieved, but adaptability to low-grade ores and contaminated sites is limited
Solution Approach 1:
The electrolytic cell system is designed to handle diverse feed streams including low-grade ores, contaminated sites, and various liquid streams containing heavy metals. The universal design with adjustable parameters (current density, electrolyte composition, membrane types) enables adaptation to different ore types and contamination levels, making it versatile for various applications.
Solution Approach 2:
The system employs adjustable operational parameters including applied voltage, current density, electrolyte composition, and flow rates that can be optimized for different feed stream characteristics. This parameter flexibility allows the same apparatus to efficiently process low-grade ores and contaminated sites with varying metal concentrations and compositions.
3Productivity
If existing treatment facilities are used, then copper extraction is achieved, but loss of valuable resources and generation of toxic byproducts occurs
Solution Approach 1:
The electrolytic cell recovers valuable metal ions from the feed stream by concentrating them in the cathode compartment through electrolysis. Instead of discarding diluted metal-containing waste streams, the system recovers and concentrates these resources, enabling metal recovery while minimizing waste generation and reducing the loss of valuable materials.
Solution Approach 2:
The system converts harmful diluted metal-containing waste streams into valuable concentrated metal products. By applying electrolysis, the harmful presence of metal contaminants is transformed into a beneficial concentration process, where metal ions are selectively deposited and recovered as pure metal or metal compounds, eliminating the need for toxic byproduct generation.
4Reliability
If chemical precipitation is used, then heavy metal removal is achieved, but toxic sludge byproducts are generated requiring costly disposal
Solution Approach 1:
The system replaces chemical precipitation processes with an electrochemical mechanism. Instead of using chemicals that form toxic sludge byproducts, the electrolytic cell uses electrical energy to drive ion migration and metal deposition. This substitution eliminates the generation of toxic sludge while maintaining effective heavy metal removal through electrochemical reactions.
Solution Approach 2:
Ion-conductive membranes act as intermediaries that enable selective ion transport without requiring chemical reagents. These membranes facilitate the separation and concentration of metal ions during electrolysis, achieving heavy metal removal while avoiding the formation of toxic byproducts associated with chemical precipitation methods.
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 increases copper recovery by 25% from heap leach mines, allows for practical metal recovery from contaminated sites, and generates non-polluting byproducts, optimizing resource utilization and reducing environmental impact.
Implementation Method 1
An electrolytic cell system with multiple compartments and selective ion conductive membranes that allows for the concentration of desired ions through unidirectional electric current
Implementation Method 2
separated from the anode compartment and the cathode compartment by a separator structure arranged to support ionic conduction of current between the anode structure and the cathode structure
Implementation Method 3
at least one ion conductive membrane positioned to contactly separate the anode compartment and the at least one additional compartment, and arranged to conduct a plurality of Hydrogen-like Cations while impeding transport of at least one selection of Anions
Data Source
AI summary
An apparatus for electrochemical modification of liquid streams employing an electrolytic cell which includes an anode compartment defined by an anode structure where oxidation is effected, containing a liquid electrolyte anolyte, and a cathode compartment defined by a cathode structure where reduction is effected containing a liquid electrolyte catholyte. In addition, the electrolytic cell includes at least one additional compartment arranged at least partially between the anode compartment and the cathode compartment and separated from the anode compartment and the cathode compartment by a separator structure arranged to supports ionic conduction of current between the anode structure and the cathode structure.