Sulfatizing Sulfide-Free Minerals with Sulfur Trioxide Gas
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Solution Overview
Problem
Existing methods for treating sulfur-free minerals are costly and risky due to the handling of sulfuric acid, and they often result in inefficient use of acidic roasting agents and inability to separate valuable metals from impurities.
Innovation Solution
A dry process of sulfatizing sulfur-free minerals with sulfur trioxide to produce metal sulfates and oxides, avoiding the production of sulfuric acid and allowing for selective recovery of desired metals, with optional recycling of unreacted sulfur trioxide and use of various reactor types for optimal conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sulfuric acid leaching is used to treat sulfide-free minerals, then metal separation is achieved, but production costs increase and safety risks arise from handling and transporting sulfuric acid
Solution Approach 1:
The patent extracts the harmful sulfuric acid handling step from the process by using sulfur trioxide gas directly for sulfatization, eliminating the need to produce, transport, and handle liquid sulfuric acid while maintaining the metal separation capability through selective sulfate formation
Solution Approach 2:
The patent changes the physical state and chemical form of the sulfur-containing reagent from liquid sulfuric acid to gaseous sulfur trioxide, which improves safety and reduces handling costs while enabling direct sulfatization of sulfide-free minerals to achieve metal separation
2Quantity of substance
If acidic roasting agents are used for sulfatization, then metal sulfates are formed, but the roasting agent is only partially utilized resulting in high consumption
Solution Approach 1:
The patent implements continuous sulfatization by maintaining a steady flow of sulfur trioxide gas through the roasted ore, ensuring complete utilization of the roasting agent for sulfate formation and eliminating partial utilization losses associated with batch processing
Solution Approach 2:
The patent uses sulfur trioxide gas as an intermediary that can be precisely dosed and completely consumed in the sulfatization reaction, replacing acidic roasting agents that are partially utilized and require excessive consumption to achieve complete metal sulfate formation
3Reliability
If conventional leaching methods are used, then metals are separated from ore, but significant wastewater problems occur
Solution Approach 1:
The patent replaces the wet leaching mechanism with a dry sulfatization process using sulfur trioxide gas, which forms metal sulfates that can be separated without generating significant wastewater, thereby maintaining metal separation efficiency while eliminating wastewater problems
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 reduces production costs and risks associated with sulfuric acid handling, enhances the efficiency of metal recovery by allowing selective separation of desired metals, and improves the yield of metal oxides and sulfates, while minimizing waste.
Implementation Method 1
contacting the sulfide-free ore and/or concentrate with gaseous sulfur trioxide (SO3) for sulfatizing the sulfide-free mineral(s) thereby forming metal sulfate(s) and metal oxide(s)
Data Source
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AI summary
The present invention provides a method of producing metal oxide(s) by sulfatizing a sulfide-free ore and/or concentrate comprising the steps of providing a sulfide-free ore and/or concentrate comprising sulfide-free mineral(s); and contacting the sulfide-free ore and/or concentrate with gaseous SO3 for sulfatizing the sulfide-free mineral(s) thereby forming metal sulfate(s) and metal oxide(s).