Polypropylene Support Particles for Copper Leaching

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for leaching copper sulfides, particularly chalcopyrite, are inefficient due to the formation of a passive layer that reduces recovery rates, and existing technologies like pressure leaching and CUPROCLOR are costly and not easily scalable, while bioleaching technologies face high investment and operational complexities.

Innovation Solution

A leaching method using non-porous polypropylene particles as a support material for agglomerating mineral concentrates, which are stable in acidic environments and resistant to abrasion and high temperatures, allowing for effective bioleaching by adhering a fine layer of mineral concentrates and facilitating improved recovery through chemical and/or biological agents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If pyrometallurgy is used to treat copper sulfide minerals, then copper can be recovered, but high capital investment, elevated operating costs, and large volumes of SO2 gas emissions are generated

Engineering Contradiction:

Improvecopper recoveryVSAvoidSO2 gas emissions

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the thermal-mechanical pyrometallurgical system with a chemical-hydrometallurgical system using acid leaching. Instead of high-temperature smelting that generates SO2 emissions, the invention uses chemical reactions between acid solutions and copper sulfide minerals to dissolve and recover copper, eliminating the harmful thermal processing step while maintaining effective copper extraction

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the operating parameters from high-temperature conditions (pyrometallurgy) to ambient or moderate temperature conditions (hydrometallurgy). By altering the temperature parameter and using chemical solutions instead of thermal energy, the process achieves copper recovery without generating SO2 emissions, thus resolving the contradiction between productivity and harmful emissions

Inventive Principle:

Principle #35Parameter changes

2Productivity

If pressure leaching is used to treat chalcopyrite, then copper recovery is improved, but the process becomes costly and not easily scalable

Engineering Contradiction:

Improvecopper recovery rateVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent changes the pressure parameter from high-pressure conditions (pressure leaching) to atmospheric or near-atmospheric pressure conditions. By using simple acid leaching at ambient pressure instead of complex high-pressure systems, the invention maintains effective copper recovery from chalcopyrite while dramatically simplifying the process equipment and scalability, thus resolving the contradiction between recovery rate and device complexity

Inventive Principle:

Principle #35Parameter changes

3Productivity

If mineral concentrates are leached without agglomeration support, then the process is simple, but recovery rates are reduced due to passive layer formation

Engineering Contradiction:

Improvemetal recovery rateVSAvoidagglomeration process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent introduces an agglomeration support material as an intermediary between the mineral concentrate and the leaching solution. This support material facilitates better contact between the acid solution and mineral surfaces, preventing passive layer formation and enhancing metal recovery. The intermediary support simplifies the overall process by improving reaction efficiency without requiring complex equipment modifications

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method enhances copper recovery rates, reduces waste and energy consumption, and provides a sustainable alternative to smelting, making it economically viable for processing previously unfeasible copper sulfide minerals like enargite, with recoveries exceeding 90% and significant energy savings.

Implementation Method 1

Adhering mineral concentrates or a metal bearing material in a stable manner to a support to form agglomerates

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

Leaching the mineral concentrate or metal bearing material by irrigating with chemical and/or biological agents present in an acidic solution

Methodology Applied

Scientific EffectChemical leaching: Chemical Bonding

Implementation Method 3

bioleaching is a solubilization methodology of metal extraction starting from the oxidation of a complex mineral matrix, using the direct or indirect action of microorganisms

Methodology Applied

Scientific EffectBioleaching: Decomposition (biological)

Implementation Method 4

stable in highly corrosive environments such as strong acid solutions

Methodology Applied

Scientific EffectChemical stability:

Data Source

PatentEP3042969B1Method of leaching of minerals concentrates

Publication Date: 2019.11.13 SOC PUNTA DEL COBRE SA

AI summary

The invention relates to new support particles for repeated use in supporting metal bearing materials or mineral concentrates during leaching operations under highly corrosive conditions and elevated temperatures. The support particles are able to float on water to aid cleaning between leaching cycles.