Sonic-Assisted Sequential Electrolysis for Calcium Extraction

The patent replaces the chemical acid leaching system with a mechanical/physical system combining ultrasonic cavitation and electrochemical leaching. Ultrasonic waves create cavitation bubbles that mechanically break down solid particles, while electrochemical reactions at electrode surfaces dissolve target elements. This substitution eliminates the need for large amounts of acid while maintaining high extraction efficiency, directly resolving the contradiction between extraction efficiency and energy consumption.

The patent changes the fundamental parameters of the extraction process by using ultrasonic frequency (20-2000 kHz) and electrochemical potential instead of acid concentration and temperature. This parameter transformation allows extraction to proceed through physical cavitation and controlled electrochemical reactions rather than aggressive chemical dissolution, reducing energy input requirements while preserving productivity.

By replacing acid-based chemical leaching with ultrasonic cavitation and electrochemical leaching, the patent eliminates the release of harmful acid waste into the environment. The ultrasonic method uses physical cavitation forces, and the electrochemical method uses controlled redox reactions at electrodes, both of which are environmentally benign compared to acid leaching that generates toxic wastewater requiring treatment.

The patent converts the harmful effect of strong acids into a beneficial process by using ultrasonic cavitation to create localized high-energy zones that promote electrochemical reactions. Instead of using harmful chemicals to achieve dissolution, the process uses controlled electrochemical reactions at electrode surfaces, turning a potentially harmful chemical approach into a clean electrochemical one.

The patent replaces the mechanical grinding system with an ultrasonic cavitation system. Instead of using high-energy ball mills or crushers to reduce particle size, ultrasonic waves generate cavitation bubbles that collapse and create localized mechanical forces, effectively breaking down solid particles in situ during the leaching process. This eliminates the separate grinding step and its associated energy consumption while maintaining extraction efficiency.

The patent performs particle size reduction as a preliminary action within the leaching process itself through ultrasonic cavitation, rather than as a separate pre-treatment step. The ultrasonic energy applied during leaching automatically breaks down solid particles to the appropriate size for efficient element dissolution, combining two operations (size reduction and leaching) into one, thereby reducing total energy consumption.