Sequential Hydrometallurgical Recovery With Carbon-Sequestering Reagents
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Solution Overview
Problem
Existing methods for carbon sequestration and metal recovery from mineral feedstocks often result in the release of alkaline species and metal compounds, with uncertain ecological effects, and lack integration with carbon capture processes.
Innovation Solution
A hydrometallurgical process that integrates carbon capture with metal recovery, using electrolytic reagents to produce acid leachants and alkali hydroxides for selective precipitation of metal hydroxides or carbonates, followed by electrolysis to regenerate reagents and scrub CO2, producing less carbon-intensive metal products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If enhanced weathering or ocean alkalinity enhancement approaches are used to sequester carbon, then carbon dioxide consumption is achieved, but release of alkaline species and metal compounds occurs with uncertain ecological effects
Solution Approach 1:
The patent converts the harmful release of alkaline species and metal compounds into a beneficial process by integrating carbon capture with hydrometallurgical value recovery. The alkaline species and metal compounds that would normally be released as waste are instead captured and processed to recover valuable metals (nickel, cobalt, magnesium, calcium) while sequestering carbon dioxide as stable carbonate minerals.
Solution Approach 2:
The patent merges two previously separate processes - carbon sequestration and metal recovery - into an integrated hydrometallurgical process. This combination allows simultaneous carbon dioxide consumption and valuable metal extraction from mineral feedstocks, transforming a potentially harmful process into a beneficial dual-purpose operation.
2Adaptability or versatility
If traditional carbon sequestration methods are used, then carbon dioxide is consumed, but integration with metal recovery processes is lacking
Solution Approach 1:
The patent creates a multi-functional process that simultaneously performs carbon dioxide sequestration and metal recovery extraction. The hydrometallurgical process is designed to handle multiple functions: leaching metals from minerals, precipitating metal hydroxides/carbonates, and sequestering carbon dioxide, all within a single integrated system.
Solution Approach 2:
The patent combines carbon capture technology with hydrometallurgical metal recovery operations, creating a versatile process that can handle both environmental (carbon sequestration) and economic (metal recovery) objectives simultaneously.
3Quantity of substance
If conventional hydrometallurgical processes are used for metal recovery, then metal values are extracted, but carbon intensity remains high
Solution Approach 1:
The patent converts the carbon-intensive nature of traditional hydrometallurgy into a carbon-negative process by integrating carbon dioxide capture. The process uses carbon dioxide that would otherwise be emitted as a resource for precipitating metal carbonates and carbonating alkaline species, turning a harmful emission into a valuable reagent.
Solution Approach 2:
The patent recovers carbon dioxide that would normally be discarded or emitted during metal recovery operations. By capturing and utilizing CO2 for precipitation and carbonation reactions, the process eliminates waste emissions and reduces the overall carbon footprint of metal production.
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
Facilitates the coproduction of low-carbon nickel, iron, calcium, and magnesium hydroxides or carbonates, suitable for various industrial applications, and enables carbon-negative steelmaking and construction materials, while reducing overall carbon footprint.
Implementation Method 1
The electrolytic process provides the acid leachant (HCl or H2SO4) and an alkali hydroxide (NaOH or KOH)
Implementation Method 2
hydrochloric or sulfuric acid leaching
Implementation Method 3
selective precipitation of metal hydroxides or carbonates in successive steps
Implementation Method 4
techniques that accelerate weathering reactions of minerals... These enhanced weathering (on land) or ocean alkalinity enhancement (at sea) approaches consume CO2
Data Source
AI summary
Processes are provided in which successive steps of hydrometallurgical value extraction may be carried out using the products of carbon capture and an electrolytic reagent-generating process. The electrolytic process provides an acid leachant and an alkali hydroxide, with the alkali hydroxide then available for use either directly as a precipitant in the hydrometallurgical steps, or available for conversion by carbon capture to an alkali metal carbonate that can in turn be used as the precipitant in the selective hydrometallurgical steps.