Hydrometallurgical Leaching Reactor Volume Reduction via Segmented Circulation
Solution Overview
Problem
Hydrometallurgical processes require large reactor volumes for efficient leaching, leading to significant investment and space constraints, as the leaching reaction is surface-dependent and particle concentration is often limited by the need for sufficient leaching solution volume.
Innovation Solution
Implementing a method and arrangement that involves a series of reactors with integrated liquid-solid matter separation and circulation of partially leached solid matter to increase solid concentration, allowing for reduced reactor size by recycling solid matter within the reactor series and using a flotation unit for selective separation of valuable metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If particle concentration is increased to speed up leaching, then leaching rate is improved, but reactor volume requirements increase
Solution Approach 1:
The leaching process is divided into multiple sequential reactors (first, second, and third reactors) where solid matter progresses through each stage. This segmentation allows for staged leaching with varying solid concentrations in different reactors, optimizing both leaching rate and volume utilization across the series.
Solution Approach 2:
Solid matter that has undergone partial leaching in earlier reactors is recovered and transferred to subsequent reactors for further processing. This recovery and reuse of partially leached solids maximizes the utilization of reactor volumes and ensures complete extraction of valuable metals.
2Ease of manufacture
If reactor volume is reduced to cut investment costs, then capital expenditure is decreased, but leaching efficiency deteriorates
Solution Approach 1:
By dividing the leaching process into multiple smaller reactors rather than one large reactor, the total reactor volume can be optimized. Each reactor in the series can operate at optimal solid concentration, maintaining high leaching efficiency while reducing individual reactor sizes and total capital investment.
Solution Approach 2:
The continuous transfer of solid matter through the reactor series ensures uninterrupted leaching action. Fresh leaching solution is continuously supplied to each reactor, maintaining optimal leaching conditions throughout the process and ensuring high efficiency despite reduced total volume.
3Quantity of substance
If solid matter is circulated within reactor series, then solid concentration is increased, but process complexity increases
Solution Approach 1:
The circulation system is segmented into specific transfer paths between defined reactors. Solid matter follows a structured route from the first to second reactor, and from second to third reactor, with clear separation points and transfer mechanisms. This segmentation manages complexity by creating organized, traceable material flows.
Solution Approach 2:
The patent introduces intermediate separation and transfer units between reactors that facilitate controlled solid matter circulation. These intermediary components manage the complexity of solid circulation by providing dedicated transfer pathways and separation points, simplifying the overall process control.
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 reduces reactor volume requirements, allowing for a quarter of the original volume to achieve the same leaching efficiency, thereby cutting costs and enhancing processing efficiency, while maintaining high zinc yield and leaching rates.
Implementation Method 1
a slurry containing solution and solid matter is removed from the one or more reactors through overflow and conveyed to a flotation unit for the liquid and solid matter separation
Data Source
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AI summary
2112057PC 17 (57) ABSTRACT The invention relates to a method for enhancing reactor volume use in a leaching stagein a hydrometallurgical process. According to the method, a concentrate or cal- cine leaching stageis carried out primarily using a plurality of reactors arranged in series, one or more reactors being provided with liquid-solid matter separation and the sepa- rated solid matter being transferred to one of the reactors in the leaching stage. Figure 2