Ore Processing Using Electrochemical Chlorine Oxidant
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ore processing methods for recovering metals and rare earth elements often rely on environmentally harmful chemicals, require high temperatures and pressures, and generate hazardous byproducts, leading to safety and environmental concerns.
Innovation Solution
A method and system utilizing on-site generated oxidants, such as electrochemically produced chlorine gas, in a low-maintenance, low-energy rotating mixing apparatus, which reduces chemical consumption and waste, and employs reducing agents like hydrogen peroxide and urea to recycle and regenerate oxidants safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional processing chemicals (mercury, cyanide, strong acids) are used for metal recovery, then metal extraction efficiency is improved, but environmental harm and safety risks increase
Solution Approach 1:
The patent changes the chemical parameters by using oxidants (chlorine, hypochlorite, ozone, peroxide) instead of conventional harmful chemicals like cyanide and strong acids. This substitution maintains metal extraction capability while eliminating environmental toxicity and safety hazards associated with traditional reagents.
Solution Approach 2:
The patent converts the harmful effects of oxidants into beneficial outcomes by carefully controlling oxidation conditions to dissolve metals from ore while preventing uncontrolled reactions. The oxidants that could potentially cause harm are instead used to selectively extract valuable metals, with the spent oxidant solution being neutralized and recycled.
2Productivity
If chlorine gas is used as oxidant under positive pressure and elevated temperatures, then metal removal from ores is improved, but safety risks and environmental discharge increase
Solution Approach 1:
The patent inverts the conventional approach by using negative pressure instead of positive pressure for chlorine gas handling. This reversal prevents chlorine leakage and improves safety by ensuring that any potential leaks are drawn into the system rather than released into the environment. The process operates at ambient or reduced temperatures rather than elevated temperatures.
Solution Approach 2:
The patent introduces an intermediary closed-loop system with scrubbers and neutralization equipment that mediates between the chlorine gas and the environment. This intermediary system captures and neutralizes spent oxidant, preventing harmful environmental discharge while maintaining efficient metal extraction.
3Productivity
If strong acids and multiple additives are co-added with oxidants, then metal dissolution is improved, but chemical expenditure and waste volume increase
Solution Approach 1:
The patent extracts and removes the need for strong acids and multiple additives by using oxidants alone or in combination with minimal additives. The oxidant-based system achieves metal dissolution without requiring the co-addition of strong acids, thereby eliminating the generation of large volumes of spent chemical waste that would require neutralization and disposal.
Solution Approach 2:
The patent implements recovery of the spent oxidant solution through neutralization and recycling. Instead of discarding large volumes of spent chemicals, the system recovers and reuses the oxidant solution, reducing both chemical expenditure and waste generation while maintaining continuous metal extraction capability.
4Productivity
If conventional mixing apparatus with stirring impellers are used, then ore-oxidant contact is improved, but energy consumption and equipment maintenance increase
Solution Approach 1:
The patent replaces the conventional mechanical stirring impeller system with an alternative mixing mechanism that reduces energy consumption and equipment wear. The specific mixing apparatus design minimizes mechanical contact with abrasive ore materials, thereby reducing maintenance requirements while maintaining effective ore-oxidant contact for efficient metal extraction.
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 enables efficient, environmentally friendly recovery of metals and rare earth elements with reduced energy consumption and waste generation, ensuring safe operation and recyclability of the processing solutions.
Implementation Method 1
employing the oxidation potential of chlorine gas and/or other on-site generated oxidants to dissolve the metals from the ore
Implementation Method 2
employs reducing agents like hydrogen peroxide and urea to recycle and regenerate oxidants safely
Data Source
AI summary
The present disclosure is a method and system for the processing of ore and ore tailings to recover metals, minerals and rare earth elements, and more particularly to a method and system for treating the ore and ore tailings using a closed loop chlorine gas oxidant treatment system using an electrochemical cell and the co-addition of an additional oxidizer such as chloric acid to enhance the dissolution of the metals from the ore which is then further processed to separate and recover the metals.