Post-Leach Thickener Control for Lower Solvent Loss in Copper Extraction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The copper extraction process, particularly in the solvent extraction phase, faces inefficiencies due to manual dosing of chemicals and high consumption of organic solvent, leading to delays and increased solvent loss due to crud formation.
Innovation Solution
A control system that measures volume and total suspended solids in the influent and effluent of the post leach thickener, using control units to automate polymer dosing and optimize organic solvent addition, reducing solids in the effluent and minimizing solvent consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If manual dosing of polymer is used in the leaching phase, then the process operation is simple, but the organic solvent consumption increases due to crud formation in the solvent extraction phase
Solution Approach 1:
The control system continuously measures total suspended solids (TSS) in the leaching phase and uses this feedback to automatically adjust polymer dosing rates. This closed-loop control optimizes thickening efficiency, reduces solids carryover to the solvent extraction phase, and minimizes crud formation that would otherwise consume organic solvent.
Solution Approach 2:
The patent replaces manual dosing operations with an automated control system that uses electronic sensors, measurement devices, and automated dosing equipment. This substitution of mechanical/manual operations with automated systems reduces organic solvent consumption while accepting increased device complexity.
2Loss of time
If manual measurements and laboratory analysis are used for TSS, then the measurement system is simple, but the process response time is delayed by several hours
Solution Approach 1:
The patent replaces manual laboratory analysis with automated in-line measurement devices that continuously monitor total suspended solids. This substitution eliminates several-hour delays by providing real-time data to the control system, enabling immediate process adjustments.
Solution Approach 2:
The control system implements continuous measurement and adjustment of polymer dosing based on real-time TSS measurements. This continuous action eliminates the intermittent nature of manual sampling and laboratory analysis, maintaining optimal process conditions without time delays.
3Loss of substance
If automated control system is implemented to reduce solids in effluent, then the organic solvent consumption decreases, but the device complexity increases
Solution Approach 1:
The control system uses continuous feedback from TSS measurement devices to automatically adjust polymer dosing, creating a closed-loop control that minimizes solids in the effluent entering the solvent extraction phase. This reduces crud formation and organic solvent loss despite increased system complexity.
Solution Approach 2:
The control system is designed to automatically monitor, analyze, and adjust process parameters without continuous human intervention. The system serves itself by using measurement data to automatically control polymer dosing, reducing organic solvent consumption while managing its own complexity through automation.
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 decreases the amount of organic solvent used in the solvent extraction phase by stabilizing polymer dosing and reducing crud formation, leading to more efficient and cost-effective copper extraction.
Implementation Method 1
first measuring units M1, M2 to measure volume and total suspended solids in an influent of the post leach thickener 13
Implementation Method 2
at least one second measuring unit M3, M4, M5 to measure at least total suspended solids relating to effluent of the post leach thickener 13
Implementation Method 3
The control unit 31 forms a control signal C1 to a polymer dosing into the influent of the post leach thickener 13
Data Source
AI summary
The invention relates to a control system for a copper extraction process having at least a leaching phase, a solvent extraction phase and an electrowinning phase, the leaching phase comprising a post leach thickener. The control system comprises first measuring units to measure volume and total suspended solids in an influent of the post leach thickener, and at least one second measuring unit to measure at least total suspended solids relating to effluent of the post leach thickener. The control system comprises also a control unit to receive measurements of the first measuring units and the second measuring units. The control unit forms a control signal to a polymer dosing into the influent of the post leach thickener, and another control signal to an organic solvent dosing in the solvent extraction phase.