Integrated Hydrometallurgical Pyrometallurgical Ore Processing
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Solution Overview
Problem
Current methods for processing copper and uranium ore are inefficient and costly, particularly due to the need for complex processing routes, high maintenance requirements, and limitations in handling changing ore grades and mineralogy, which results in reduced plant availability and metal recoveries.
Innovation Solution
A multi-stage pyrometallurgical process involving heap leaching with an acidic iron-containing solution, followed by flotation and smelting, which allows for the recovery of copper and uranium using existing equipment and accommodating varying ore grades and mineralogy, while minimizing capital expenditure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional processing routes are used for copper and uranium ore, then each metal value can be recovered, but the process complexity increases and plant availability decreases
Solution Approach 1:
The patent combines the treatment of copper and uranium into a single integrated processing route. The ore is leached to recover both copper and uranium simultaneously, eliminating the need for separate processing lines. This merging of processes reduces overall system complexity and improves plant availability by removing interdependencies between separate processing units.
Solution Approach 2:
The leaching process is designed to perform multiple functions simultaneously: it extracts copper, uranium, and precious metals in a single operation. This multi-functional approach replaces what would traditionally require multiple specialized processing units, thereby reducing device complexity while maintaining the ability to recover all valuable metals.
2Reliability
If tails leaching is used to recover uranium, then uranium recovery is achieved, but scale formation increases maintenance requirements
Solution Approach 1:
The patent extracts uranium from the leach solution through solvent extraction, separating it from the scaling-prone environment of traditional tails leaching. By using a dedicated solvent extraction circuit, uranium can be recovered efficiently without the calcium and potassium ions that cause gypsum and jarosite scale formation in conventional tails leaching systems.
Solution Approach 2:
The patent introduces solvent extraction as an intermediary process between leaching and uranium precipitation. This intermediary step allows uranium to be selectively extracted from the leach solution, avoiding direct contact with the scaling environment and eliminating the need for frequent maintenance of leaching equipment.
3Productivity
If stirred tanks are used for uranium leaching, then leaching efficiency is improved, but capital expenditure increases
Solution Approach 1:
The patent employs a heap leaching approach where the leaching medium flows through a stationary ore heap, eliminating the need for expensive, complex stirred tank equipment. The system uses simple, low-cost infrastructure that can be easily constructed and modified, achieving effective uranium recovery without the high capital expenditure associated with mechanical agitation systems.
Solution Approach 2:
The patent uses hydraulic flow through the ore heap to achieve leaching, replacing mechanical stirring with fluid dynamics. The leach solution is pumped through the ore bed, allowing efficient mass transfer and uranium dissolution without requiring expensive mechanical agitation equipment, thereby reducing capital expenditure while maintaining leaching efficiency.
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 enhances copper and uranium recoveries, reduces maintenance needs, and improves plant robustness and economics by decoupling processing steps and utilizing existing equipment, leading to higher total metal recoveries and cost-effectiveness.
Implementation Method 1
subjecting the heap of the ore material to an acidic heap leach using an iron containing acidic leach solution in the presence of an oxygen containing gas
Implementation Method 2
The ferric iron leaches the copper sulphide minerals, (eg. chalcopyrite, bornite and chalcocite), liberating copper and more ferrous iron
Implementation Method 3
The ferrous iron is then reoxidised to ferric iron by oxygen from the air
Implementation Method 4
subjecting the ripios to flotation to produce a copper containing ripios concentrate and tailings
Implementation Method 5
subjecting the ripios concentrate to a smelting process to produce a smelted copper product
Data Source
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AI summary
A process for recovering copper, uranium and one or more precious metals from an ore material, including: a. forming a heap of the ore material; b. subjecting the heap of the ore material to an acidic heap leach using an iron containing acidic leach solution in the presence of an oxygen containing gas, and producing a pregnant leach solution and a ripios; c. subjecting the ripios to flotation to produce a copper containing ripios concentrate and tailings; and d. subjecting the ripios concentrate to a smelting process to produce a smelted copper product. e. recovering copper and uranium from the pregnant leach solution.