Vanadium Extraction from Shale Using Ion Exchange Resin
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Solution Overview
Problem
Current methods for extracting vanadium from shale, such as high-temperature baking and strong acid leaching, result in low vanadium leaching and recovery rates, along with significant pollution and energy consumption, and are complicated by high impurity levels and alkali consumption.
Innovation Solution
A method involving grinding shale into fine powders, mixing with an additive, heating to 850-950°C, followed by water and acid immersion, ion exchange adsorption using a styrene-divinylbenzene based macroporous anion-exchange resin, and calcination to produce vanadium oxide (V2O5), which simplifies the process and improves leaching and recovery rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature baking and strong acid leaching are employed to destroy the mica crystal structure, then the vanadium can be made soluble and transformed into vanadate, but the process results in low vanadium leaching rate and recovery rate along with significant pollution and energy consumption
Solution Approach 1:
The patent changes the chemical parameters by using a specific additive composition (NaCl:Na2CO3 in 1:0.04-0.12 mass ratio) and controlling baking temperature (850-950°C) and time (30-90 min) to optimize vanadium extraction efficiency while reducing harmful effects
Solution Approach 2:
The patent introduces an intermediary additive system that facilitates the destruction of mica crystal structure and enhances vanadium solubility without requiring excessive strong acids or alkalis, thereby reducing pollution and energy consumption while improving leaching rate
2Productivity
If sodium chloride-water leaching is used with additive dosage exceeding 12 wt.%, then the vanadium can be extracted, but serious pollution of Cl2 and HCl occurs
Solution Approach 1:
The patent optimizes the additive composition parameters by using NaCl:Na2CO3 in a specific ratio of 1:0.04-0.12 mass ratio, which improves vanadium extraction efficiency while controlling harmful Cl2 and HCl pollution through optimized chemical composition
Solution Approach 2:
The patent applies local quality by using a specific combination of additives (NaCl and Na2CO3) in precise proportions to achieve targeted chemical reactions that enhance vanadium extraction while minimizing harmful byproducts
3Productivity
If 2 mol/L NaOH solution is used as leaching agent, then the vanadium can be extracted, but high alkali consumption occurs and the leached solution contains large amount of silicon impurities
Solution Approach 1:
The patent changes the leaching agent composition from pure NaOH to a mixed additive system (NaCl:Na2CO3 in 1:0.04-0.12 ratio), which improves vanadium extraction efficiency while reducing alkali consumption and silicon impurity content in the leached solution
4Productivity
If 4 mol/L sulfuric acid solution is used as leaching agent, then the vanadium can be extracted, but high acid consumption and high impurity content occur
Solution Approach 1:
The patent changes the leaching agent from concentrated sulfuric acid (4 mol/L) to a optimized additive mixture (NaCl:Na2CO3 in 1:0.04-0.12 ratio), which maintains high vanadium extraction efficiency while significantly reducing acid consumption and impurity content in the leached solution
5Productivity
If pressurized acid leaching-extraction is used, then the vanadium can be extracted, but large amount of energy is consumed
Solution Approach 1:
The patent changes the leaching conditions by using optimized additive composition (NaCl:Na2CO3 in 1:0.04-0.12 ratio) at controlled temperatures (850-950°C for baking, 50-90°C for leaching), which improves vanadium extraction efficiency while reducing energy consumption compared to pressurized acid leaching
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 achieves high vanadium leaching and recovery rates, with 98-99% adsorption, desorption, and precipitation rates, and a purity of 99.12-99.63% V2O5, while reducing pollution and energy consumption, and simplifying the industrialization process.
Implementation Method 1
performing ion exchange adsorption on the combined solution using a styrene-divinylbenzene based macroporous anion-exchange resin
Implementation Method 2
The method uses an additive including NaCl and Na2CO3... heating the mixture to a temperature of between 850 and 950° C. at a heating rate of 5-9° C./min, and baking the mixture for between 30 and 90 min
Implementation Method 3
precipitating the purified solution to yield poly ammonium vanadate
Implementation Method 4
calcining the poly ammonium vanadate at a temperature of between 450 and 530° C. for between 20 and 50 min to yield vanadium oxide (V2O5)
Data Source
AI summary
A method for extracting vanadium from shale, the method including: a) grinding the shale into fine powders, mixing the fine powders with an additive in a mass ratio of 1:0.04-0.12 to yield a mixture, heating the mixture to a temperature of between 850 and 950° C. at a heating rate of 5-9° C./min, and baking the mixture for between 30 and 90 min; b) immersing the product in water and acid respectively to yield a first solution and a second solution, combining the two solutions, and performing ion exchange adsorption on the combined solution using a styrene-divinylbenzene based macroporous anion-exchange resin; and c) performing desorption, purification, and precipitation to yield poly ammonium vanadate, and calcining the poly ammonium vanadate at a temperature of between 450 and 530° C. for between 20 and 50 min to yield V2O5.