Surfactant Treatment for Sulfidic Ore Moisture Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of metal values from sulfidic ores in smelting operations is limited by the upper temperature limitations of the smelting furnace, and increasing the moisture content of ores to enhance production is hindered by issues such as caking and clogging of transport systems.
Innovation Solution
Applying an aqueous solution or dispersion containing a surfactant to the sulfidic ore, preferably in the form of an aqueous foam, allows for higher moisture content and increased ore processing without transport issues, enabling more ore to be smelted per time period.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the moisture content of sulfidic ore is increased to enhance metal production, then more ore can be processed per time period, but caking and clogging of conveyor belts and transport systems occurs
Solution Approach 1:
A hydrophobic coating is applied to the sulfidic ore particles as an intermediary layer that repels water. This coating allows the ore to be handled at higher moisture contents during smelting while preventing the water from causing caking and clogging in transport systems. The hydrophobic coating acts as a mediator between the moisture required for increased productivity and the transport system that must remain reliable.
2Productivity
If additional metal sulfide is added to increase production, then metal yield increases, but the upper temperature limitations of the smelting furnace are exceeded
Solution Approach 1:
The moisture content parameter of the sulfidic ore is changed and increased before smelting. This parameter change allows more ore to be fed into the furnace, increasing metal production. The evaporating moisture absorbs excess heat, effectively controlling the furnace temperature within acceptable limits while enabling higher throughput.
3Productivity
If moisture is added to sulfidic ore to reduce furnace temperature, then more ore can be fed to the furnace, but transport system clogging occurs
Solution Approach 1:
The hydrophobic coating serves as a protective intermediary layer on the ore particles. This coating allows the ore to tolerate higher moisture contents needed for increased processing rates while preventing the water from creating harmful caking and clogging effects in the transport system. The coating decouples the moisture benefit from the clogging harm.
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 allows for increased metal production by enabling higher moisture content ores to be processed without clogging problems, thereby maximizing the amount of ore that can be smelted within a given time, enhancing overall metal yield.
Implementation Method 1
An aqueous solution or dispersion comprising a surfactant is brought into contact with the sulfidic ore
Implementation Method 2
the moisture will evaporate, reducing the temperature of the upper furnace
Implementation Method 3
the sulfur in the ore is oxidized, resulting in an exothermic reaction, whereby the heat generated is sufficient to melt the metal
Data Source
AI summary
A process for improving recovery of metal values in a smelting operation of the type wherein sulfidic ores are pyrometallurgically reduced. The process includes adding an anionic or non-ionic surfactant and blends thereof to the ore.