Electrolysis: processes – compositions used therein – and methods – Electrolytic synthesis – Preparing single metal
Patent
1994-10-03
1996-10-29
Niebling, John
Electrolysis: processes, compositions used therein, and methods
Electrolytic synthesis
Preparing single metal
205580, 204233, 204234, 204235, 204236, C25C 112
Patent
active
055693709
DESCRIPTION:
BRIEF SUMMARY
INTRODUCTION
This invention concerns an electrochemical system and process and more particularly a system and process which will enable many electrochemical processes to dissolve and recover metals from their natural or artificial compounds at a commercial scale and on a continuous basis.
DISCUSSION OF PRIOR ART
Pyrometallurgical processes such as the KIVCET process and the ISASMELT process and hydrometallurgical processes such as the solvent extraction process; the Arbiter process using ammonia; the ElMCO Electro Slurry Process and the DEXTEC Copper Process among others were introduced in the last three or so decades for the extraction of metals from their ores. Most of these processes require considerable inputs of energy and produce considerable waste products or are limited in their commercial application.
The most appealing in terms of environmental effect, low cost and good recoveries and quality of product are electrolytic processes. These were the claims for the DEXTEC copper process which was developed in Australia. In this process the electrochemical dissolution and precipitation of the copper is carried out in a single cell where the dissolution of the fine sulfide copper ore using air and electricity in the anode section is separated by a diaphragm from the cathode section where copper is deposited by electrolysis. On a small scale the DEXTEC process produces copper metal in simple steps at low energy and reagent cost with minimum environmental effect. It appears, however, that the DEXTEC process is not suitable for commercial scale production due to the following difficulties. of the copper ions through the diaphragm bag and is probably too slow for commercial application. being blocked, up by small ore particles or by scale build-up. precipitated with the copper at the cathode.
The electrical chemical system proposed in this invention overcomes the shortcomings of the conventional diaphragm cell described above and allow electrochemical reaction similar to the DEXTEC process to be carded out on a continuous commercial scale.
Other electrochemical processes recently disclosed in the prior art are as follows:
U.S. Pat. No. 4,181,588; Wong; Jan. 1, 1980
In this process, lead sulfide is leached with ferric chloride/sodium chloride solution in a separate vessel. The liquor is then filtered and introduced in an electrochemical cell where metallic lead is precipitated at the anode and the ferrous chloride passes through a diaphragm to the anode where it is oxidised to ferric chloride and re-cycled to the leaching tank.
U.S. Pat. No. 4,159,232; Bacon et al; Jun. 26, 1979
This process is aimed at obtaining copper and iron metal from an iron ore and nickel and iron metal from a nickel ore. Fine ore is dissolved in a leaching vessel with strong hydrochloric acid and sodium chloride. Contamination with oxygen is avoided as it will affect the electrolytic process. The leach liquor is separated and fed into the cathode compartment of the electrolytic cell where the copper is deposited and ferrous chloride and hydrogen is produced. Ferrous chloride diffuses to the anode and is oxidised to ferric chloride which is returned to the leaching tank. The hydrogen produced in the cathode is used to reduce some of the ferrous chloride to metallic iron.
This U.S. Patent discloses one variation where some copper sulfide is added to at least one anode compartment and then circulated to other anode compartments. There is no means of agitating the anode slurry as introduction of air Would be harmful to the chemical process of this US Patent.
U.S. Pat. No. 3,926,752; Loretto et al; Dec. 16, 1975
This patent concerns the recovery of metallic copper and also metallic iron from a copper ore by leaching with ferric chloride and hydrochloric acid in the anode compartment. A diaphragm separates the anode compartment from the cathode compartment. The ferrous chloride produced is oxidised to ferric chloride in the anode. Metallic iron is recovered in another cathode compartment after the feed solution is stripped of copper by
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Mee Brendan
Niebling John
RMG Services Pty. Ltd.
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