US20140144788A1 - System and process for the continuous recovery of metals - Google Patents
System and process for the continuous recovery of metals Download PDFInfo
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- US20140144788A1 US20140144788A1 US14/009,130 US201214009130A US2014144788A1 US 20140144788 A1 US20140144788 A1 US 20140144788A1 US 201214009130 A US201214009130 A US 201214009130A US 2014144788 A1 US2014144788 A1 US 2014144788A1
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25C—PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR
- C25C1/00—Electrolytic production, recovery or refining of metals by electrolysis of solutions
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
- C22B3/02—Apparatus therefor
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
- C22B3/04—Extraction of metal compounds from ores or concentrates by wet processes by leaching
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Definitions
- This invention relates to mining and metallurgical refining and more particularly to systems and processes for solvent extraction and electroextraction of metals.
- Zinc precipitation involves crushing and grinding ore containing the precious metal (e.g., gold), and then combining the ground ore with a water and caustic cyanide solution.
- the resulting mud-like pulp is moved to a settling tank where the coarser gold-laden solids move to the bottom via gravity, and a lighter first pregnant solution of water, gold, and cyanide moves to the top and is removed for further processing.
- the gold-laden solids are agitated and aerated in a separate agitated leach process where oxygen reacts to leach the gold into the caustic water and cyanide forming a second pregnant solution.
- the second pregnant solution passes through a drum filter which further separates remaining solids.
- the first and second pregnant solutions are combined with zinc to precipitate out the dissolved gold.
- the resulting precipitated gold concentrate may then be smelted to produce refined gold bar.
- Electrowinning typically involves extracting a precious metal such as gold from an electrolyte.
- activated carbon is combined with a pregnant solution in a batch process step.
- the activated carbon adsorbs the precious metal contained within the pregnant solution, and becomes “loaded” with the precious metal.
- the loaded carbon is then descaled by sequentially washing it in three batch process steps to remove ore residue.
- the loaded carbon is moved to a washing tank and then the tank is filled with a dilute acid solution.
- the washing tank is then drained and the used dilute acid solution is pumped away and disposed of.
- the same washing tank is then filled with water to rinse remaining acid from the loaded carbon. The water becomes slightly acidic during this process.
- the used slightly acidic rinse water is also drained from the washing tank, pumped away, and disposed of.
- the tank is filled with a caustic solution, and the activated carbon is washed in the caustic solution.
- the used caustic solution is then drained from the tank, pumped away, and disposed of.
- An optional final water rinse step may be performed by again, filling the washing tank with rinse water or pH-neutral solution, rinsing caustic residue from the loaded carbon, and then draining the tank of the used rinse water/solution so that it may be pumped away for disposal.
- the loaded carbon is removed from the washing tank and then added to a strip solution comprising water, a caustic substance, and cyanide to form a strip solution/loaded carbon slurry.
- the strip solution/loaded carbon slurry goes through an elution process where high temperatures and pressures are used to “re-leach” gold from the loaded carbon into the caustic strip solution to form an electrolyte solution.
- the electrolyte solution is then moved to a batch electrolytic cell where wire (e.g., reticulated) or plate cathodes collect deposited gold concentrate during electrolysis. After the batch electrowinning process, the cathodes are manually removed from the cell for cleaning, so that gold concentrate deposited thereon can be removed from the cathodes and readied for smelting.
- cathodes After cleaning, the cathodes are then manually replaced within the electrolytic cell, and the entire sequence of batch washing, elution, and electrowinning processes is repeated.
- Some cathodes e.g., wire cathodes, due to their small interstices
- FIG. 27 schematically illustrates a conventional metal recovery process 9000 as described above.
- Activated or reactivated carbon 9560 is suspended within a pregnant solution in a conventional batch carbon loading step 9700 .
- the pregnant solution is generally formed by percolating a dilute cyanide solution through a heap leach pad of crushed mineral-laden ore (e.g., by way of a drip or spray irrigation having a concentration of about 0.5 to 1 pound of sodium cyanide, potassium cyanide, or calcium cyanide per ton of solution).
- the active carbon adsorbs the desired material (e.g., gold, silver, platinum, lead, copper, aluminum, platinum, uranium, cobalt, manganese) from the pregnant solution, it becomes “loaded” carbon 9570 and enters a batch acid wash process 9100 configured for descaling the loaded carbon 9570 as previously discussed.
- desired material e.g., gold, silver, platinum, lead, copper, aluminum, platinum, uranium, cobalt, manganese
- FIG. 28 shows one example of a conventional batch acid washing system 9100 ′.
- Loaded carbon 9570 enters an acid wash vessel 9120 which receives dilute acid from a dilute acid tank 9140 via a pump 9132 .
- Dilute acid overflow is captured by a sump pump 9150 which moves the overflow to a neutralizing tank 9160 .
- Contents of the neutralizing tank 9160 may be moved to a secondary holding tank via a pump 9136 .
- the conventional batch acid wash process 9100 continues by draining the acid wash vessel 9120 of dilute acid solution, and then filling the vessel 9120 with an aqueous rinse solution. Overflow of aqueous rinse solution is captured by sump pump 9150 which moves the overflow to a neutralizing tank 9160 and/or a holding tank.
- the process 9100 may continue by draining the vessel 9120 of aqueous rinse solution, and then filling the vessel 9120 with a caustic rinsing agent. Overflow of the caustic rinse may likewise be captured by sump pump 9150 and moved to a neutralizing tank 9160 and/or a holding tank (not shown).
- a conventional batch elution process 9200 typically involves feeding descaled loaded carbon 9500 and/or loaded carbon directly from an adsorption system 9700 into a strip vessel 9240 .
- Strip vessel 9240 is generally a large cylindrical tank of material suitable for holding reagents at an elevated pressure and temperature (e.g., 138 degrees C.-148 degrees C.).
- the descaled loaded carbon 9500 is maintained within the strip vessel 9240 at high temperatures and pressure in the presence of a caustic aqueous strip solution comprising cyanide.
- spent carbon 9550 is removed from the strip vessel 9240 (e.g., via carbon transfer pump 9232 ), and is moved to a carbon handling system or carbon regeneration system 9300 ′ or process 9300 .
- Hot electrolyte solution 9421 is formed within the strip vessel 9240 as material previously adsorbed onto the loaded carbon leaches into the strip solution.
- the hot electrolyte solution 9421 is also removed from the strip vessel 9240 and passes through a heating skid 9250 or equivalent heat exchanger for cooling before entering a conventional batch electrowinning system 9400 ′ or process 9400 .
- Cooling of hot electrolyte solution 9421 to form a lower temperature electrolyte solution 9530 is generally necessary to reduce the risk of flashing within a conventional batch electrolytic metal recovery cell 9420 .
- the heating skid 9250 also serves to recycle energy by warming cooler barren solution 9540 which exits the electrolytic metal recovery cell 9420 (e.g., at about 66 degrees C.) and/or barren solution 9237 which exits the barren solution storing tank 9220 before re-entering the strip vessel 9240 to serve once again as a strip solution re-leaching agent. Warming of the cooler barren solution 9237 , 9540 to form a hot barren solution 9239 may also be done using a heater in addition to, or in lieu of said heating skid 9250 .
- One or more pumps 9234 , 9236 are generally used to transfer barren solution back to the strip vessel 9240 . Additional reagent from a reagent handling system and/or more pregnant solution may be added to barren solution tank 9220
- electrolyte solution 9530 enters a conventional batch electrolytic metal recovery cell 9420 which operates in batch cycles.
- a series of parallel plate cathodes are placed within close proximity and the electrolyte solution 9530 is pumped in and agitated around the cathodes.
- Body portions of the cell 9420 carry an opposing charge with respect to the cathodes, and by virtue of electrolysis, ions contained in the electrolyte solution 9530 are subsequently deposited on the cathodes as a cathode sludge concentrate of the recovery metal or as a solid cathode plating.
- cathodes are typically removed simultaneously from the cell 9420 in a batch process step in order to collect the recovered metal.
- the cathode may be flexed to delaminate and remove the hard cathode plating from the cathode.
- the concentrate is separated from the cathode in a subsequent process and the cathodes are then recycled.
- Sludge concentrate may collect at the bottom of the cell 9420 and may be removed periodically.
- An electrowinning pump box 9440 and pump 9430 may be employed to temporarily store spent electrolyte (i.e., barren solution) which is removed from the cell 9420 between batches.
- problems associated with the abovementioned conventional acid wash systems 9100 ′ and processes 9100 are numerous.
- the systems utilize independent, non-continuous, “batch” process steps which require constant manpower, downtime, and energy (e.g, continually draining and refilling the same acid wash vessel 9120 with different rinsing agents).
- such conventional batch acid wash processes 9100 typically discard expensive acid, caustic, and/or other reagents after each use. This increases overhead (e.g., purchasing costs, disposal costs) and creates unnecessary harm to the environment.
- the process 9200 employs batch process steps which require constant manpower and energy (e.g., continually draining and refilling the strip vessel 9240 with new strip solution, hot barren solution 9239 , and loaded carbon 9500 each time more electrolyte solution 9530 is needed for electrowinning 9400 ).
- This increases overhead costs (e.g., labor, maintenance), complicates production scheduling, and may cause harm to the environment.
- conventional metal recovery systems 9000 ′ are bulky and require large plant layout footprints as demonstrated by FIG. 23 , when compared to a system 100 ′ for the continuous recovery of metals according to the invention ( FIG. 22 ) which will be described hereinafter.
- an object of the invention to provide an improved metal recovery system which is configured for continuous carbon loading/adsorption, continuous washing and stripping of loaded carbon, continuous electrolyte formation, continuous electrowinning, and continuous regeneration/re-activation, thereby avoiding the aforementioned problems associated with conventional batch metal recovery processes.
- Another object of the invention is to improve the efficiency of a metal recovery process (e.g., by minimizing radiation losses, reducing power consumption, minimizing reagent consumption, and preventing carbon breakdown and electrolyte loss).
- Yet another object of the invention is to prevent or minimize carbon loss and reagent waste.
- Another object of the invention is to maximize total metal recovery.
- Another object of the invention is to provide a metal recovery system which is configured to cost less and have a smaller footprint area than conventional metal recovery systems.
- Another object of the invention is to provide a system and process for the recovery of metals which is configured to operate at higher flow rates, temperatures, and/or pressures than conventional processes.
- Yet even another object of the invention is to reduce the percentage by weight of unrecovered metal present in spent electrolyte/barren solution.
- a system for the continuous recovery of metals comprises, in accordance with some embodiments of the invention, at least one of a continuous acid wash system configured for receiving a continuous, uninterrupted inflow of loaded carbonaceous particulate and delivering a continuous, uninterrupted outflow of descaled loaded carbonaceous particulate; a continuous elution system configured for receiving a continuous, uninterrupted inflow of a strip solution containing a descaled loaded carbonaceous particulate and delivering a continuous, uninterrupted outflow of electrolyte solution; and a continuous electrowinning system configured for receiving a continuous, uninterrupted inflow of electrolyte solution, delivering a continuous uninterrupted outflow of a barren solution, and continuously and uninterruptedly forming a cathode sludge concentrate.
- Each of the continuous acid wash system, the continuous elution system, and the continuous electrowinning system are generally configured to operate simultaneously without periodic interruptions which are common with conventional batch metal recovery processes.
- the system may comprise an integrated carbon regeneration system operatively connected to the continuous elution system.
- a continuous carbon loading/adsorpsion system may be operatively connected to and upstream of the continuous acid wash system.
- the continuous acid wash system may be operatively connected to the continuous elution system; for example, via a holding tank between said continuous acid wash system and said continuous elution system.
- One or more pumps may be provided to facilitate the transportation of slurry and solids within the system.
- the continuous elution system is operatively connected to the continuous electrowinning system and comprises one or more screens or filters configured to prevent carbonaceous particulate from passing to the continuous electrowinning system.
- the continuous acid wash system may comprise a chamber adapted for retaining a fluidization medium; an inlet adapted for receiving a feed containing loaded carbonaceous particulate; a fluidized bed distribution panel or other means adapted for fluidizing the loaded carbonaceous particulate in the presence of said fluidization medium; an opening adapted to pass loaded carbonaceous particulate and fluidization medium from the chamber; and a screen adapted to filter loaded carbonaceous particulate from a fluidization medium.
- the continuous elution system may comprise a splash vessel, a continuous elution vessel, and a flash vessel, wherein the splash vessel is operatively connected to the continuous elution vessel in series, the continuous elution vessel is operatively connected to the flash vessel in series, and the splash vessel is operatively connected to the flash vessel in parallel.
- the continuous electrowinning system comprises an electrolytic cell having a cell body configured to maintain electrolyte solution at a high pressure and/or temperature; at least one anode; at least one cathode; an inlet configured for receiving a continuous, uninterrupted influent stream of electrolyte solution; a first outlet configured for discharging a continuous, uninterrupted effluent stream of spent electrolyte solution; a second outlet configured for removing cathode sludge concentrate; and a residence chamber configured to continuously transfer electrolyte solution from said inlet to said first outlet and increase residence time of said electrolyte solution between said at least one anode and said at least one cathode.
- the residence chamber may comprise one or more channels which are configured to provide a forced flow of electrolyte solution therein which is strong enough to continuously dislodge and/or transport cathode sludge concentrate along said one or more channels and eventually out of said residence chamber.
- the continuous elution vessel may comprise an influent manifold and an effluent manifold which communicate with the first outlet and inlet of the electrolytic cell, respectively, and may further comprise a fluidized bed and/or one or more internal baffles which are configured to torture flow paths and increase a residence time of loaded carbonaceous particulate therein.
- a valve configured to flash solution leaving the continuous elution vessel and entering the flash vessel may also be provided.
- the continuous acid wash system may comprise at least one of an acid solution, an aqueous solution, and a caustic solution.
- the continuous elution system may comprise a solution containing at least one of a carbonaceous particulate loaded with a precious metal, an electrolyte solution, spent carbonaceous particulate, a caustic, an aqueous component, and cyanide.
- the continuous electrowinning system may comprise an electrolyte solution or cathode sludge concentrate.
- Each of the continuous acid wash system, the continuous elution system, and the continuous electrowinning system may be configured to increase a residence time, pressure, or temperature of solutions or slurries contained therein and may comprise a screen or filter element.
- the continuous acid wash system may comprise multiple washing vessels, each washing vessel comprising a chamber adapted for retaining a fluidization medium; an inlet adapted for receiving a feed containing a loaded carbonaceous particulate; a fluidized bed distribution panel or other means adapted for fluidizing and cleaning the loaded carbonaceous particulate with said fluidization medium; an opening adapted to pass loaded carbonaceous particulate and fluidization medium from the chamber; and a screen adapted to filter loaded carbonaceous particulate from fluidization medium.
- the continuous acid wash system may comprise an acid wash tank containing an acidic fluidization medium, an aqueous rinse tank containing a substantially pH-neutral aqueous solution, and a caustic rinse tank containing an alkaline fluidization medium.
- the continuous acid wash system may comprise one or more recirculation tanks for collecting spent fluidization medium, and one or more weirs, channels, valves, or drains for capturing spent fluidization medium.
- the continuous electrowinning system may be configured for continuous and uninterrupted collection and removal of said cathode sludge concentrate and may comprise one or more channels defined between a cathode, an anode, and an insulator.
- the one or more channels may comprise portions of a helix, spiral, coil, compound curve, 3D-spline curve, figure-8, or serpentine shape and the cathode and anode may be formed as sleeves or tubes which are separated by said insulator.
- the carbon regeneration system is operatively connected to both the continuous elution system and the continuous carbon loading/adsorpsion system, and the continuous carbon loading/adsorpsion system is operatively connected to said continuous acid wash system.
- a process for the continuous recovery of a metal comprises, in accordance with some embodiments, continuously feeding a continuous wash system with particulate loaded with a metal; continuously washing said loaded particulate within the continuous wash system to descale the loaded particulate; continuously removing descaled loaded particulate from said continuous wash system; continuously loading a continuous elution system with said descaled loaded particulate; continuously removing electrolyte solution from said continuous elution system; continuously feeding a continuous electrowinning system with said electrolyte solution; continuously removing spent electrolyte solution from said continuous electrowinning system; and, continuously delivering said spent electrolyte solution to said continuous elution system; wherein each of the continuous wash system, the continuous elution system, and the continuous electrowinning system are configured to allow the above steps to be performed simultaneously, without the periodic interruptions required for conventional batch processes.
- the process may further comprise continuously removing spent particulate from the continuous elution system; continuously feeding said spent particulate to a carbon regeneration system; continuously removing cathode sludge concentrate from the continuous electrowinning system; and/or forming said loaded particulate by continuously adsorbing metal onto said particulate in a continuous carbon loading/adsorption system which is similar to or identical to said continuous wash system.
- the particulate may be one of a carbonaceous particulate, a polymeric adsorbent, or an ion-exchange resin.
- FIGS. 1 and 2 schematically illustrate a system and method for the continuous recovery of metals according to some embodiments
- FIG. 3 is a flowchart of a three-sequence continuous acid wash operation according to some embodiments
- FIGS. 4 and 5 outline steps of a continuous acid washing process according to some embodiments
- FIGS. 6 and 7 depict a washing tank which may be used in the acid wash process shown in FIGS. 1-5 ;
- FIG. 8 shows an acid wash system comprising a plurality of the washing tanks depicted in FIGS. 6 and 7 ;
- FIGS. 9 and 12 schematically illustrate a system and method of continuous elution according to some embodiments.
- FIG. 10 is an isometric view of a continuous elution system according to some embodiments.
- FIG. 11 shows a side cutaway view of the continuous elution system of FIG. 10 ;
- FIGS. 13 and 19 schematically illustrate a system and method of continuous electrowinning according to some embodiments;
- FIG. 14 shows a top plan view of a continuous electrowinning system according to some embodiments.
- FIGS. 15 and 16 are vertical and isometric cutaway views, respectively, of a continuous electrowinning system taken on line XV-XV in FIG. 14 ;
- FIG. 17 is a detailed view of FIG. 15 , showing the particulars of an inlet according to some embodiments;
- FIG. 18 is a transverse cutaway view of an electrowinning cell along line XVIII-XVIII in FIG. 14 ;
- FIG. 20 shows a process for regenerating/reactivating spent carbon according to some embodiments
- FIGS. 21 and 22 show a system for the continuous recovery of metals
- FIG. 23 shows a conventional batch system for the recovery of metals
- FIG. 24 shows an alternative to the washing tank shown in FIGS. 6-8 or an apparatus to be used for continuous carbon loading/adsorption;
- FIG. 25 shows a detailed isometric view of the chamber shown in FIG. 24 ;
- FIG. 26 is a cutaway view of the chamber shown in FIG. 25 ;
- FIG. 27 shows a conventional system for the recovery of metals.
- FIG. 28 shows a conventional acid wash process
- FIG. 29 shows a conventional batch elution process
- FIG. 30 shows a conventional batch electrowinning process.
- a plant system 100 ′ or process 100 for the continuous recovery of a metal from mined ore may comprise, in accordance with some embodiments of the invention, a continuous acid wash system 10 ′ or process 10 , a continuous elution system 20 ′ or process 20 , a continuous electrowinning system 40 ′ or process 40 , a continuous carbon regeneration system 30 ′ or process 30 , and a continuous carbon loading/adsorption system 70 ′ or process 70 .
- Activated/reactivated carbon 56 (which may be derived for example, from coconut shells or charcoal), or alternatively, an equivalent particulate substance such as loaded polymeric adsorbent or loaded ion-exchange resin, is subjected to a continuous carbon adsorption process 70 where it spends a time of residence suspended in a pregnant solution which contains a dissolved target recovery metal such as gold, silver, copper, aluminum, platinum, uranium, chromium, zinc, cobalt, manganese, or lead.
- the continuous carbon loading/adsorption system 70 ′ or process 70 may comprise, for example, an apparatus as shown in FIGS. 6 and 7 or FIGS. 24-26 which serves to fluidize the activated/reactivated carbon 56 within the pregnant solution.
- the carbon 56 undergoes a continuous acid wash process 10 .
- Descaled loaded carbon 50 leaving the continuous acid wash process 10 enters a holding tank 60 filled with a strip solution containing one or more reagents (e.g., water, caustic, and cyanide) to form a slurry 51 of strip solution and descaled loaded carbon 50 .
- the slurry 51 enters a continuous elution process 20 where the temperature and/or the pressure of the slurry 51 is increased and the target recovery metal previously adsorbed by the carbon is re-leached into the strip solution thereby forming an electrolyte solution 53 which may be used for a continuous electrowinning process 40 .
- Barren solution (i.e., spent electrolyte) 54 leaving the continuous electrowinning process 40 is returned to the continuous elution process 20 and/or the holding tank 60 for re-use.
- a solids fraction 55 of spent carbon, depleted of its target recovery metal via the continuous elution process 20 moves to a carbon regeneration process 30 for reactivation before being re-used in the continuous carbon loading/adsorption process 70 .
- a continuous acid wash process 10 may generally comprise the steps of: feeding 1004 loaded carbon 57 into a continuous acid wash system 10 ′, fluidizing 1006 incoming loaded carbon 57 in a dilute acid solution within a first acid wash tank 12 , extracting 1008 loaded carbon from the acid wash tank 12 , screening 1010 the extracted loaded carbon to remove the dilute acid solution, capturing 1012 dilute acid solution 57 c separated from the loaded carbon, optionally processing 1014 the captured dilute acid solution 57 c (e.g., filtering, additives, pH adjust), and recycling the dilute acid solution 57 c by feeding 1016 the dilute acid solution 57 c back into the acid wash tank 12 .
- Acid-rinsed loaded carbon 57 a which has undergone an acid bath in acid wash tank 12 is fed 1018 into a second aqueous rinse tank 14 containing water or another pH-neutral aqueous rinse solution 57 d , and then fluidized 1020 in said aqueous rinse tank 14 .
- the process 10 further comprises extracting 1022 rinsed loaded carbon 57 b from the aqueous rinse tank 14 , screening 1024 the extracted rinsed loaded carbon 57 b to remove aqueous rinse solution 57 d , capturing 1026 separated aqueous rinse solution 57 d separated from the rinsed loaded carbon 57 b , optionally processing 1028 the captured aqueous rinse solution 57 d (e.g., filtering, additives, pH adjust), and recycling the aqueous rinse solution 57 d by feeding 1030 the aqueous rinse solution 57 d back into the aqueous rinse tank 14 .
- processing 1028 the captured aqueous rinse solution 57 d e.g., filtering, additives, pH adjust
- Rinsed loaded carbon 57 b which has undergone washing in aqueous rinse tank 14 is fed 1032 into a third caustic rinse tank 16 containing a caustic rinse solution 57 e , and is then fluidized 1034 in said caustic rinse tank 16 .
- the continuous acid wash process 10 further comprises extracting 1036 descaled loaded carbon 50 from the caustic rinse tank 16 , screening 1038 the extracted descaled loaded carbon 50 to remove caustic rinse solution 57 e , capturing 1040 caustic rinse solution 57 e separated from the descaled loaded carbon 50 , optionally processing 1042 the captured caustic rinse solution 57 e (e.g., by filtering, providing additives, or adjusting pH), and recycling the caustic rinse solution 57 e by feeding 1044 the solution 57 e back into the caustic rinse tank 16 .
- the continuous acid wash process 10 may comprise the step of providing one or more pumps 13 a , 13 b for re-circulating the rinsing solutions in each of the aforementioned tanks 12 , 14 , 16 .
- a fourth aqueous rinse cycle (not shown) may be provided, and one of ordinary skill in the art would acknowledge that any one or more of the aforementioned washing steps may be repeated or alternated.
- acid wash tank 200 may comprise an acid wash tank having a first chamber 220 , a first fluidized bed distribution panel 221 , a first inlet 222 , a first recirculation inlet 223 a , a first recirculation outlet 223 b , a first weir 224 , a first screen 226 , a first overflow outlet 227 , a first discharge outlet 228 , a first recirculation tank 229 , a bottom wall 260 , an inner tubular wall 266 , an outer tubular wall 268 , and a first channel 282 defined between the inner tubular wall 266 and outer tubular wall 268 adjacent the first weir 224 .
- tanks 200 , 200 ′, and 200 ′′ may be constructed as “universal” or “interchangeable” tanks. Moreover, tanks 200 , 200 ′, 200 ′′ may be configured with tubular (e.g., cylindrical pipe or prismatic extrusion) shapes as shown in order to reduce manufacturing costs. Any one or more of tanks 200 , 200 ′, and 200 ′′ may be replaced with a tank of dissimilar scale or a tank 2000 as shown in FIGS. 24-26 , which will be described hereinafter.
- tubular e.g., cylindrical pipe or prismatic extrusion
- a first fluidization medium comprising a dilute acid or anti-scaling agent solution may occupy the first acid wash tank 200 .
- the first fluidization medium may comprise a solution of 1-10% vol/vol mineral acid, such as nitric acid or hydrochloric acid configured to dissolve carbonate scale.
- incoming loaded/reloaded carbon 57 moves over the first screen 226 and flows into the first chamber 220 of the first acid wash tank 200 via the first inlet 222 . Fluid which may be present with the incoming loaded/reloaded carbon 57 is drained and enters the first recirculation tank 229 . The screened loaded carbon subsequently falls downwardly along the first screen 226 and towards the first fluidized bed distribution panel 221 and is fluidized by the first fluidization medium.
- a slurry of acid-rinsed loaded carbon 57 a and residual first fluidization medium exits the first acid wash tank 200 through the first discharge opening 228 and enters a second aqueous rinse tank 200 ′ through a second inlet 232 .
- the acid-rinsed loaded carbon 57 a may be conveyed to the tank 200 ′ using only gravitational forces, or the acid-rinsed loaded carbon 57 a may be conveyed to the tank 200 ′ using one or more slurry pumps (not shown).
- a second fluidization medium such as a substantially pH-neutral aqueous scrubbing solution or a hot water may occupy the second aqueous rinse tank 200 ′.
- the second recirculation outlet 233 b may be operatively connected to the first recirculation inlet 223 a to fluidize loaded/reloaded carbon 57 within the first washing tank 200 .
- one or more pumps may be disposed between the outlet 233 b and inlet 223 a.
- the third fluidization medium may comprise other reagents, for instance 1-10% wt sodium cyanide (NaCN).
- the third fluidization medium may be heated (e.g., 20-100 degrees C.).
- a slurry of rinsed loaded carbon 57 b and second fluidization medium flows over a third screen 246 or equivalent filter and into the third chamber 240 .
- the third screen 246 serves to filter the slurry by separating its second fluidization medium liquid fraction from its rinsed loaded carbon 57 b solid fraction.
- the separated second fluidization medium is maintained in a third recirculation tank 249 .
- third fluidized bed distribution panel 241 After passing over third screen 246 , twice-rinsed loaded carbon particulate subsequently falls towards a third fluidized bed distribution panel 241 and is fluidized within the third chamber 240 by a flow of third fluidization medium entering the third recirculation inlet 243 a and passing through the panel 241 .
- Clarified third fluidization medium rises above the highest level of suspension of the loaded carbon fluidized within the tank 200 ′′ and pours over a third weir 244 and into a third channel 286 , where it exits the caustic rinse tank 200 ′′ via outlet 247 and optionally feeds the third recirculation inlet 243 a as indicated by the dotted line path taken by caustic rinse solution 57 e.
- a slurry of caustic-rinsed, descaled loaded carbon 50 and third fluidization medium exits the third caustic rinse tank 200 ′′ through third discharge opening 248 and may be subsequently screened or filtered for further processing.
- de-scaled loaded carbon 50 within the slurry may be separated from the third fluidization medium liquid fraction by a screen or filter (not shown) and then added to a strip solution of water, caustic, and cyanide in a holding tank 60 for use in downstream continuous elution 20 and electrowinning 40 processes.
- fluidized bed portions 221 , 231 , 241 may be replaced with, or used in combination with one or more mechanical or forced air agitators (not shown) to suspend loaded carbon particulate in fluidization medium.
- the number of chambers 220 , 230 , 240 per system 10 ′ may be greater or less than what is shown.
- the relative sizes, dimensions and/or volumes of chambers 220 , 230 , 240 may vary.
- the chambers 220 , 230 , 240 may be dimensioned and proportioned similarly.
- any one chamber 220 , 230 , 240 may be compartmentalized into multiple chambers.
- the system 10 ′ or portions thereof may be used to continuously load activated carbon in a continuous carbon loading/adsorption process 70 .
- infeed particulate may comprise activated or reactivated carbon and the first, second, and third fluidization mediums may comprise a pregnant solution (e.g., sodium cyanide (NaCN) solution containing a dissolved precious metal).
- a pregnant solution e.g., sodium cyanide (NaCN) solution containing a dissolved precious metal
- Electrolyte solution 53 may be conveyed to the continuous electrowinning process via an effluent manifold 28 b provided on the continuous elution vessel 24 .
- Spent slurry 51 c of strip solution and spent carbon is flashed by a valve 29 and enters into a flash vessel 25 where steam is captured and returned to the splash vessel 22 via a steam return 21 to help heat and pressurize the splash vessel 22 in an efficient manner.
- the resulting concentrated spent slurry 51 d is separated into solid 55 and liquid 52 fractions using a dewatering screen 26 .
- the liquid fraction 52 of concentrated spent slurry 51 d may be returned to holding tank 60 , and the solids fraction 55 of the concentrated spent slurry 51 d (i.e., spent de-watered carbon) may be sent to a carbon regeneration process 30 for reactivation.
- Barren solution 54 returning from a continuous electrowinning process 40 is generally heated with an immersion heater 27 and then sent back to the continuous elution vessel 24 via one or more pumps 23 and an influent manifold 28 a.
- Slurry flowing within the continuous elution vessel 24 may contain incoming hot pressurized slurry 51 a and barren solution 54 leaving a continuous electrowinning system 40 ′ or process 40 .
- Fluidizing chamber 350 may be fed by an influent manifold 28 a connected to the continuous elution vessel 24 via one or more influent ports 326 having influent port mounts 322 .
- the influent manifold 28 a may instead be connected directly to the one or more sidewalls 310 of the continuous elution vessel 24 .
- a stream of barren solution 54 flows into the continuous elution vessel 24 via the influent manifold 28 a .
- the stream enters and fills the fluidizing chamber 350 and flows through fluidized bed 320 to help fluidize and suspend carbon particulate within the residence chamber 340 as it travels along the serpentine flow path 51 b.
- the effluent manifold 28 b may be connected directly to the one or more sidewalls 310 of the continuous elution vessel 24 , or may be connected to the vessel 24 via one or more effluent ports 316 having effluent port mounts 312 .
- loaded carbon While in the residence chamber 340 of the continuous elution vessel 24 , loaded carbon is exposed to strip solution reagents under high temperature and high pressure conditions.
- the reagents in the strip solution act to strip the loaded carbon of its previously adsorbed metal contents (e.g., gold), and “re-leach” it into the solution to form an electrolyte solution.
- One or more screens or filters 324 may be provided between the residence chamber 340 and the effluent manifold 28 b in order to extract a clarified stream of electrolyte solution 53 from the continuous elution vessel 24 and/or prevent carbon particulate from passing downstream of the effluent manifold 28 b .
- the placement of said screens or filters 324 may be at the interface between the effluent ports and the one or more sidewalls 310 of the continuous elution vessel 24 .
- the screens or filters 324 may be provided in other locations without limitation, for instance: within the effluent manifold 28 b , within the continuous elution vessel 24 , at the interface between the effluent manifold 28 b and mounts 312 , or downstream of said effluent manifold 28 b .
- one or more seals or gaskets may be placed between the influent 28 a or effluent 28 b manifolds and the continuous elution vessel 24 .
- Fluidized carbon and solution within residence chamber 340 continues to move along the serpentine flow path 51 b until it is either removed through effluent manifold 28 b to be used as electrolyte, or passes through outlet 328 .
- the outlet 328 may comprise an outlet mount 330 and/or an outlet seal 329 for connecting to a valve 29 .
- the valve 29 may be of any sort known in the art, such as a ball or cone valve without limitation, and one would appreciate that the valve may be separately coupled to, or formed integrally with either one or both of the continuous elution vessel 24 and the flash vessel 25 .
- additional piping sections may be added between the second outlet 328 and the valve 29 if the distance between the continuous elution vessel 24 and the flash vessel 25 is large.
- the stream of hot pressurized spent slurry 51 c exiting the continuous elution vessel 24 “flashes” as it passes through the valve 29 .
- the resulting mixture of gas vapors, fluids, and solids enters the lower pressure flash vessel 25 , where heated steam is diverted back to the splash vessel 22 via steam return piping 21 .
- Unvaporized spent solution and spent carbon leave the flash vessel 25 in a stream of concentrated spent slurry 51 d .
- the concentrated spent slurry 51 d may comprise a barren solution liquid fraction 52 , and a solids fraction 55 of spent carbon substantially-free of previously-adsorbed precious metal (e.g., gold).
- the stream of concentrated spent slurry 51 d may be subsequently screened or filtered by a dewatering screen 26 .
- a liquid fraction 52 of the concentrated spent slurry 51 d is separated from the solid fraction 55 by dewatering screen 26 and returned to the holding tank 60 for re-use as strip solution.
- One or more pumps may be provided to move the liquid fraction 52 to the holding tank 60 .
- the solids fraction 55 of dewatered spent carbon is sent to a carbon regeneration process 30 comprising a regeneration kiln 35 or other means for reactivating the carbon.
- Dewatering screen 26 may be provided as a two-stage screen, wherein a first stage removes a majority of the liquid fraction 52 from the spent carbon solids fraction 55 , and a second stage removes residual caustic and/or cyanide from the solids fraction 55 of spent carbon before it enters a regeneration kiln 35 or wash vessel. Accordingly, equipment in the carbon regeneration system 30 ′ is not damaged.
- FIG. 12 schematically illustrates a continuous elution process 20 according to some embodiments.
- a slurry 51 of descaled loaded carbon 50 and a caustic strip solution comprising water and cyanide is produced 1048 .
- the slurry 51 may be formed and stored in a holding tank 60 .
- the slurry 51 is then pumped 1050 into the splash vessel 22 which is configured to elevate the temperature and/or pressure of the descaled loaded carbon/strip solution slurry 51 .
- a hot pressurized slurry 51 a of loaded carbon/strip solution is formed and moved 1054 from the splash vessel 22 to the continuous elution vessel 24 .
- the hot pressurized slurry 51 a is kept within the vessel 24 for an increased residence time 1056 , for instance, by providing a fluidized bed 320 alone or in combination with a plurality of baffles 318 in order to elongate the physical travel path of the hot pressurized slurry 51 a between the inlet 304 of the vessel 24 and the outlet 328 .
- the physical travel path may be for instance, a serpentine flow path 51 b as shown.
- the loaded carbon in the hot pressurized slurry 51 a is stripped of its adsorbed precious metal by reagents in the caustic strip solution. Accordingly, the caustic strip solution dissolves the precious metal into itself thereby forming an electrolyte solution 53 .
- the electrolyte solution 53 is screened to remove carbon particulate therefrom and is extracted 1064 from the continuous elution vessel 24 . Subsequently, the electrolyte solution 53 is fed 1066 to a continuous electrowinning system 40 ′ (e.g., into a continuous electrolytic metal extraction cell 42 ) for precious metal recovery.
- a continuous electrowinning system 40 ′ e.g., into a continuous electrolytic metal extraction cell 42
- barren solution 54 is continuously removed 1070 from the continuous electrowinning system 40 ′ and pumped 1072 back into the continuous elution vessel 24 either directly, or indirectly (e.g., via a barren solution holding tank (not shown) or immersion heater 27 ).
- Solution and carbon are continuously removed from the continuous elution vessel 24 , and the liquid fraction of the solution “flashed” or at least partially vaporized 1058 with a valve 29 before entering the flash vessel 25 .
- the process 20 further comprises recovering 1060 heated steam from the rapid evaporation of exiting spent slurry 51 c , and piping 1062 the steam back to the splash vessel 22 in order to efficiently increase 1052 the temperature and/or pressure of the first vessel 22 .
- Concentrated spent slurry 51 d is removed 1074 from the flash vessel 25 , and then dewatered 1076 to separate the spent liquid fraction 52 from the spent solids fraction 55 .
- the solids fraction 55 comprises dewatered carbon which is sent 1078 to a carbon regeneration system 30 ′, and the spent liquid fraction 52 of the concentrated spent slurry 51 d is sent 1080 to the holding tank 60 for re-use.
- fluidized bed 320 may be replaced with, or used in combination with one or more mechanical agitators (not shown) to suspend loaded carbon particulate.
- the number of baffles 318 in the continuous elution vessel 24 may be greater or less than what is shown, in order to provide the residence times and flow rates required for a particular process.
- one or more additional vessels 22 , 24 , 25 may be added to a continuous elution system 20 ′ and placed in series or parallel with other vessels 22 , 24 , 25 to increase throughput.
- two or three continuous elution vessels 24 may be directly or indirectly coupled to each other in parallel, and placed in series between a single splash vessel 22 and a single flash vessel 25 .
- FIG. 13 shows a continuous electrowinning process 40 according to some embodiments.
- the process 40 comprises continuously providing an electrolyte solution 53 , continuously feeding the electrolyte solution 53 to a continuous electrolytic metal extraction cell 42 , extracting cathode sludge concentrate 53 f from the cell 42 in a sludge removal stream 53 g , continuously extracting barren solution 54 from the cell 42 and using said barren solution 54 to feed a continuous elution vessel 24 within a continuous elution process 20 .
- the continuous electrowinning system 40 ′ largely comprises a continuous electrolytic metal extraction cell 42 comprising a cell body 406 having a first end 440 , a second end 480 , one or more sidewalls 482 extending therebetween, a base 404 having one or more mounts 402 , at least one inlet 410 for receiving a continuous influent stream of a precious metal-containing electrolyte solution 53 , at least one first outlet 420 for providing continuous egress of a spent electrolyte stream 53 d and barren solution 54 contained therein, and at least one second outlet 430 for providing egress of cathode sludge concentrate 53 f collected within the cell 42 .
- the second outlet 430 may be configured for continuous egress of collected cathode sludge concentrate 53 f , or the second outlet 430 may be configured for intermittent egress of said collected cathode sludge concentrate 53 f .
- a first chamber 405 Within the cell body 406 is provided a first chamber 405 , a second chamber 407 , a third chamber 408 , and a residence chamber 460 comprising one or more elongated channels 462 .
- the channels 462 are configured to increase residence time of the electrolyte solution 53 and provide a forced flow electrolyte stream 53 b of electrolyte solution 53 therein which is strong enough to dislodge and/or displace cathodic sludge concentrate which forms and builds up within the channels 462 .
- the one or more channels 462 may comprise, for example, a portion of a helix, double-helix, coil, spiral, serpentine, spline, compound curve, and may extend in curvilinear paths.
- the residence chamber 460 may be concentrically situated between the first chamber 405 and the third chamber 408 .
- the first chamber 405 may be configured to be devoid of electrolyte and/or cathodic sludge concentrate during operation, and may generally serve as a space-filler bounded between first end 440 , inner anode 477 , and baffle 450 .
- the space filling first chamber 405 generally provides channels 462 within the residence chamber 460 with a larger radius, thereby increasing the overall effective length and total surface area of the channels 462 exposed to forced flow electrolyte streams 53 b contained therewithin.
- the third chamber 408 serves to temporarily hold and/or transport spent electrolyte streams 53 d from within the cell 42 to one or more first outlets 420 .
- the first end 440 may be configured as an annular panel having a central opening exposing the first chamber 405 , rather than as a solid continuous circular panel as shown.
- the one or more first outlets 420 may be provided at an upper portion of the cell 42 where overflow is likely to be more clarified and free from cathode sludge concentrate.
- Each channel 462 may be defined between at least one anode 474 , at least one cathode 472 , and one or more insulators 476 extending therebetween.
- one or more anodes 474 and one or more cathodes 472 are provided as sleeve portions which alternate concentrically between an outer anode 479 and an inner anode 477 with each sleeve portion having a different radius.
- the anodes 474 and cathodes 472 are radially separated and maintain a uniform spacing by one or more spacing protuberances 473 projecting from said one or more cathodes 472 .
- the one or more protuberances 473 may alternatively extend from the anodes 474 alone, or may extend from both anodes 474 and cathodes 472 without limitation. However, by providing protuberances 473 on the one or more cathodes 472 , a small amount of extra cathodic surface area is provided for precipitating cathodic sludge concentrate out of the forced flow electrolyte stream 53 b during electrolysis.
- the one or more insulators 476 prevent short circuit between the negatively charged anodes 474 and positively charged cathodes 472 and may serve as flexible, tolerance-compensating gaskets which delineate the cross-sectional boundary of each channel 462 and build/concentrate the forced flow electrolyte stream 53 b within each channel 462 .
- each anode 474 may communicate with one or more anode terminals 442 .
- Anode terminals 442 may comprise, for example and without limitation, a fastener 442 a such as a pin or screw, a clamping member 442 b such as a nut, flange, or head, a terminal lead 442 c connected to a ground or power source, a conductive washer 442 d or other clamping member, an insulative bushing 442 e to prevent electrical currents from passing to surrounding portions of the cell 42 , a thread or equivalent securing feature 442 f provided on said fastener 442 a , a conductive support 442 h comprising a complimentary thread or equivalent securing feature 442 g for communicating with said thread or equivalent securing feature 442 f , and a receiving portion 442 i provided within the conductive support 442 h for engaging and supporting one or more anodes 474 .
- anodes 474 are generally tubular cylindrical sleeves and therefore, receiving portions 442 i may be provided as small straight or generally arcuate slits.
- receiving portion 442 i may comprise a plurality of conductive clamps, spring clips, or pegs extending from the support 442 h which straddle and secure an anode 474 thereto.
- the continuous electrowinning system 40 ′ may be provided with a cylindrical cell body 406 , a flat circular upper first end 440 , and a generally frustoconical lower second end 480 .
- the frustoconical shape of the lower second end 480 generally aids in channeling collected heavy cathode sludge concentrate 53 f to the second outlet 430 for removal.
- the first end 440 may be secured to the cell body 406 via an annular flange 445 which may be electrically neutral or positively charged with the rest of cathodic cell body 406 .
- the first end 440 may comprise a series of sandwiched panels, such as one or more ground or electrically-neutral panels 447 , one or more anodic panels 444 , and one or more insulative panels 446 .
- the one or more insulative panels 446 may comprise a gasket, such as a polytetrafluoroethylene (PTFE) insulating gasket.
- PTFE polytetrafluoroethylene
- One or more fasteners 441 or adhesives may be provided to secure the first end 440 to the body 406 and/or to secure sandwiched panels 444 , 446 , 447 together.
- a series of fasteners 441 may be provided around a perimeter of the first end 440 to secure the first end 440 to the flange 445 .
- the fasteners 441 may be insulated, for example, with a sheath, coating, bushing, or washer of non-conductive material such as high molecular weight polyethylene (HMWPE), polyvinylidene fluoride (PVDF), polypropylene, or polyvinylchloride (PVC). Moreover, the fasteners 441 may serve the dual purpose of securing the first end 440 to the body 406 and also securing sandwiched panels 444 , 446 , 447 together.
- HMWPE high molecular weight polyethylene
- PVDF polyvinylidene fluoride
- PVC polyvinylchloride
- an influent stream of electrolyte solution 53 at a higher-than-ambient pressure and temperature continuously enters the cell 42 via inlet 410 .
- the electrolyte solution 53 may contain metal ions of copper, gold, silver, platinum, lead, zinc, cobalt, manganese, aluminum, or uranium, without limitation.
- the continuous electrowinning system 40 ′ is preferably maintained at a higher-than-ambient temperature (e.g., around 88 degrees Celsius) and/or pressure.
- the influent stream of electrolyte solution 53 may come from an upstream electrolyte holding tank (not shown), a continuous elution system 20 ′, or a combination thereof.
- the inlet 410 may be formed from a portion of a pipe or tubing having one or more sidewalls 412 and may further comprise an inlet mount 414 having a flange, seal, valve, pipe fitting, or equivalent connector for integration with the continuous elution system 20 ′.
- Inlet 410 comprises one or more openings 413 (e.g., through said one or more sidewalls 412 ), which are configured to feed said one or more channels 462 of the residence chamber 460 with incoming electrolyte solution 53 . Though not shown, a plurality of openings 413 may be provided per channel 462 .
- the influent stream of electrolyte solution 53 may be split into a plurality of dispersed influent streams 53 a , each entering different channels 462 .
- a separate inlet 410 may be provided for each channel 462 .
- the openings 413 may be configured to provide uniform or non-uniform flow rates across each channel 462 or provide similar electrolyte residence times for each channel 462 .
- one or more insulators 417 e.g., an insulation pad
- the one or more insulators 417 may encircle the one or more openings 413 to ensure that incoming electrolyte solution 53 from dispersed influent streams 53 a does not form, plate, or sludge within the openings 413 , particularly adjacent cathodes 472 .
- channels 462 may be configured to allow the dispersed influent streams 53 a of electrolyte solution 53 to flow forcedly through the channels 462 in a forced flow electrolyte stream 53 b which follows a uniform helical or spiral path as shown.
- the channels 462 may also be configured to direct the dispersed influent streams 53 a along straight paths, serpentine paths, compound curve paths, or complex 3D-spline curve paths so long as they can support a forced flow electrolyte stream 53 b therein and provide a sufficient residence time of electrolyte between an anode 474 and cathode 472 .
- Channels 462 may shrink or grow in circumference or change in overall or cross-sectional shape and/or size as they extend within the residence chamber 460 ; however, it is preferred that channels 462 remain uniform in cross-section, direction, and/or anode-cathode spacing throughout their entire length. While not shown, since channels 462 located at greater radial distances from the center of the cell 42 are longer and will generally have higher residence times than inner channels 462 , the number of turns of inner channels 462 (e.g., channels adjacent inner anode 477 and first chamber 405 ) may be adjusted to be greater than the number of turns for outer channels 462 (e.g., channels more proximate the outer anode 479 and third chamber 408 ).
- inner portions of residence chamber 460 may be greater in height than outer portions of residence chamber 460 , in order to lengthen the effective length of inner channels 462 (adjacent the first chamber 405 ).
- Portions of baffle 450 adjacent the residence chamber 460 and third chamber 408 are generally open so as to allow channels 462 to continuously deliver spent electrolyte streams 53 d to the third chamber 408 and collected cathode sludge concentrate 53 f formed in the channels 462 to the second chamber 407 .
- baffle 450 may comprise an anodic layer 452 , a middle electrically-neutral insulator 454 to support said one or more anodes 474 and cathodes 472 , and a support structure 456 for supporting the insulator 454 and anodic layer 452 .
- the insulator 454 may be made of a chemically-robust material such as ultra-high molecular weight polyethylene (UHMWPE) and may be cruciform in shape as shown.
- UHMWPE ultra-high molecular weight polyethylene
- a plurality of receiving portions 458 such as notches may be provided to the insulator 454 to hold, space, insulate, and support the one or more anodes 474 and cathodes 472 ; however, other holding means such as pegs, spring clips, or clamps may be provided.
- the insulator 454 may be connected to the support structure 456 with one or more fasteners, adhesives, or other connecting means, and the support structure 456 may be connected to the body 406 by conventional means such as bolting, forming, adhering, welding, or supporting on a flange or shelf.
- the anodic layer 452 may serve to close off the first chamber 405 and prevent electrolyte 53 in the forced flow electrolyte stream 53 b from entering said first chamber 405 .
- the support structure 456 may be a lattice structure such as a mesh screen or supporting member such as a crossbar which spans a width of the cell body 406 .
- Support structure 456 is generally configured not to inhibit electrolyte flowing from the channels 462 to the third chamber 408 , or inhibit the passage of cathode sludge concentrate 53 f to the second chamber 407 .
- electrolyte solution 53 forcibly flows through the one or more channels 462 in the residence chamber 460 , a large electric potential is placed between the one or more anodes 474 and one or more cathodes 472 in order to effectively “plate-out” sludge concentrate onto the one or more cathodes 472 .
- the channels 462 may be configured such that cathodic sludge concentrate initially forms on or adjacent to the one or more cathodes 472 , but will not actually bond or “plate” to the cathodes 472 and will instead flush down the channels 462 and/or become suspended in the forced flow electrolyte streams 53 b .
- any sludge concentrate that may settle to bottom of a channel 462 may also be washed down and eventually swept out of the channels 462 and into second chamber 407 by the forced flow electrolyte streams 53 b .
- Sludge concentrate may be flushed out of the one or more channels 462 by virtue of: gravitational forces acting on inclined surfaces, high flow rates of forced flow electrolyte streams 53 b passing through the one or more channels 462 , increased turbulence within each channel 462 , and/or by virtue of small cross-sectional areas provided to each channel 462 .
- the outflow 53 c of the residence chamber 460 will generally comprise a liquid carrier component of barren solution 54 which is substantially-free of dissolved precious metal, and a solid precipitate component comprising cathodic sludge concentrate which has been discharged from the channels 462 by the forced flow electrolyte stream 53 b .
- the heavier solids may follow a sludge precipitate stream 53 e before settling in a mass of collected cathode sludge concentrate 53 f within the second chamber 407 adjacent the second end 480 .
- Barren solution 54 travels via spent electrolyte stream 53 d into the third chamber 408 and continuously leaves the cell 42 through outlet 420 .
- cathodic sludge concentrate formation may occur within the third chamber 408 (for example, on or around inner portions of cathodic sidewall(s) 482 ).
- any cathode sludge concentrate 53 f formed within the third chamber 408 will typically settle and eventually end up in second chamber 407 with the rest of the collected cathode sludge concentrate 53 f.
- the first outlet 420 may be formed from a portion of a pipe or tubing having one or more sidewalls 422 and may further comprise a first outlet mount 424 having a flange, seal, valve, pipe fitting, or equivalent connector for integration with a continuous elution system 20 ′.
- a first outlet mount 424 having a flange, seal, valve, pipe fitting, or equivalent connector for integration with a continuous elution system 20 ′.
- Captured cathode sludge concentrate 53 f may be removed from the cell 42 intermittently or continuously via second outlet 430 .
- the underflow, or sludge removal stream 53 g of cathode sludge concentrate 53 f may proceed to a holding tank, be pumped away for further refining, or may be dumped into a container and transported to a smelter.
- the second outlet 430 may be formed from a portion of a pipe or tube having one or more sidewalls 432 and may further comprise a second outlet mount 434 having a flange, seal, valve, pipe fitting, nozzle, tap, or equivalent connector for integration with a holding tank or smelting apparatus.
- the cross-section of residence chamber 460 may vary, so long as one or more channels 462 therein are formed between at least one anode 474 and at least one cathode 472 which are separated from each other by one or more insulators 476 .
- Channels may extend linearly (resembling an elongated pipe), helically, in a cascade of connected, horizontally-arranged, and vertically-displaced “figure-8s”, or in any continuous path in 3-D space which is configured to provide a “forced flow” of electrolyte solution.
- a residence chamber 460 may comprise one or more channels 462 therein which simply extend as long straight pipe sections tilted at an angle with respect to horizontal.
- FIG. 19 schematically illustrates a continuous electrowinning process 40 according to some embodiments.
- the process 40 comprises providing 1082 an electrolyte solution 53 having an elevated temperature or pressure with respect to ambient conditions.
- the electrolyte solution 53 may be produced from a continuous elution process 20 and may comprise water, cyanide, caustic, and a dissolved metal (e.g., gold, copper, silver, platinum, aluminum, lead, zinc, cobalt, manganese, or uranium) therein.
- the electrolyte solution 53 is continuously fed 1084 (e.g., at a predetermined flow rate) into a continuous electrolytic metal recovery cell 42 which is preferably maintained 1086 at a higher-than-ambient temperature and/or pressure.
- the cell 42 may comprise a series of nested anode sleeves 474 and cathode sleeves 472 , wherein adjacent sleeves have a different electrical potential or charge.
- the sleeves are spaced concentrically and radially evenly with respect to each other so that any two neighboring sleeves hold an opposite charge 1088 .
- One or more insulators 476 may be placed between the anodes 474 and cathodes 472 to define a plurality of channels 462 (e.g., helical channels) and simultaneously prevent arcing between the anodes and cathodes.
- the process 40 further comprises subjecting 1090 the electrolyte solution 53 to a longer residence time within a continuous electrolytic metal recovery cell 42 .
- Electrolyte solution 53 maintained within the channels 462 is forced through the channels 462 and walls thereof by small pressure differentials between the inlet 110 and the first 120 outlet and/or small pressure differentials between the inlet 110 and the second 130 outlet. As the electrolyte solution 53 moves through the channels 462 , cathodic sludge concentrate precipitates out of the electrolyte solution 53 until the solution becomes weaker in concentration and eventually substantially-free of precious material 1092 .
- Precipitating concentrate from the sludge precipitate stream 53 e is continuously collected 1094 within second chamber 407 , and collected cathode sludge concentrate 53 f may be extracted 1098 continuously or intermittently or a combination thereof.
- a stream of barren solution 54 (which is substantially devoid of precious metal) is continuously extracted 1096 from the cell 42 via outlet 420 , and may be fed to a continuous elution vessel 24 within a continuous elution process 20 .
- FIG. 20 shows a carbon regeneration process 30 according to some embodiments.
- a solids fraction 55 of concentrated spent slurry 51 d comprising spent de-watered carbon is sifted with a screen 32 to separate out spent carbon fines 55 b .
- the spent carbon fines 55 b are placed in a carbon fines holding tank 34 .
- the remaining course spent carbon 55 a is sent to a regeneration kiln 35 (or other means for regeneration such as a chemical, steam, or biological process).
- Hot reactivated carbon 55 c is removed from the regeneration kiln 35 and quenched in a carbon quench tank 36 .
- a slurry of cooled regenerated carbon and fluid moves to a dewatering screen 37 via pump 33 .
- dewatered activated/reactivated carbon 56 is moved to a continuous carbon loading/adsorption process 70 .
- the fluid underflow which comprises cool reactivated carbon slurry 55 d , is moved to the carbon fines holding tank 34 .
- FIG. 21 shows a continuous metal recovery system 100 ′ according to some embodiments of the invention comprising a continuous acid wash system 10 ′, a continuous elution system 20 ′, a continuous electrowinning system 40 ′, and a carbon regeneration system 30 ′.
- FIGS. 22 and 23 serve to compare scale plant layouts and overall footprints.
- FIG. 22 shows the system 100 ′ for the continuous recovery of metals according to FIG. 21 and FIG. 23 comprises a conventional system 9000 ′ for the batch recovery of metals using “batch” process steps.
- the system 100 ′ according to the invention is smaller in size than the conventional system 9000 ′ depicted in FIG. 23 .
- system 100 ′ is also more efficient and environmentally-friendly.
- FIG. 24 shows an alternative to the washing tanks 200 , 200 ′, 200 ′′ shown in FIGS. 6-8 .
- an acid wash tank 2000 is provided, which may replace acid wash tank 200 .
- Acid wash tank 2000 comprises a wash chamber 2020 having a fluidized bed panel 2021 spanning the length of the wash chamber 2020 with pore sizes smaller than the mean particle size of loaded/reloaded carbon, one or more adjustable mounts 2007 , 2009 which may be individually raised, lowered, or pivoted on a rack or linkage (not shown for clarity) to change the inclination angle of the chamber 2020 with respect to a skid 2002 , a recirculation inlet 2023 a provided below the fluidized bed panel 2021 , and a recirculation outlet 2023 b provided above the fluidized bed panel 2021 .
- Recirculation outlet 2023 b comprises one or more overflow outlets 2027 , each provided with at least one washable/replaceable recycle screen 2008 , which maintains loaded/reloaded carbon 57 within the chamber 2020 and filters exiting dilute acid solution 57 c .
- Recycle screens 2008 may be conveniently provided between bolted flange members of the overflow outlets 2027 and may comprise built-in peripheral gaskets.
- FIGS. 25 and 26 show more detailed views of the chamber 2020 shown in FIG. 24 .
- Recirculation inlet 2023 a may comprise one or more adjustable nozzles 2011 which serve to fluidize loaded/reloaded carbon 57 .
- the nozzles 2011 may be individually or collectively angularly adjusted and “set” to a fixed angle, in order to: compensate for various inclinations of the chamber 2020 , prevent buildup of loaded/reloaded carbon 57 , and counteract backflow within the chamber 2020 caused by eddy currents surrounding interior baffles 2018 .
- Chamber 2020 may, as shown, be constructed in clamshell form, with a number of fasteners 2004 connecting upper and lower clamshell portions together.
- One or more additional gaskets may be employed between the upper and lower clamshell portions to form a seal, or the fluidized bed panel 2021 itself may be provided with peripheral gasketing material properties to provide a seal between the upper and lower clamshell portions.
- a first filter 2001 is provided at an inlet 2022 to the acid wash tank 2000 .
- the first filter 2001 comprises a housing 2003 which serves to collects influent loaded/reloaded carbon slurry 57 ′, a first screen 2026 which serves to separate loaded/reloaded carbon 57 from carrier fluid 57 f present in the slurry 57 ′, a first filter outlet 2006 which serves to transfer strained loaded/reloaded carbon 57 from within the upper housing 2003 to the wash chamber 2020 , a recirculation tank 2029 which collects carrier fluid 57 f separated from the liquid fraction of the influent slurry 57 ′, and one or more clamps 2005 which removably attach the housing 2003 to the recirculation tank 2029 with the first screen 2026 extending therebetween, thereby allowing periodic cleaning and/or replacing of the first screen 2026 .
- Recirculation tank 2029 may be configured to continuously redistribute carrier fluid 57 f to a holding tank (not shown) or may simply comprise a valve for batch removal of the collected carrier fluid
- a second filter 2024 is provided adjacent a first channel 2082 extending from the fluidized bed panel 2021 to an outside portion of the wash chamber 2020 .
- First channel 2082 is configured to provide egress of acid-rinsed loaded carbon 57 a resting on/around/above fluidized bed panel 2021 after it has undergone a predetermined residence time of acid washing within the chamber 2020 .
- the acid-rinsed loaded carbon 57 a is filtered by a second screen 2036 , and the strained solids fraction of the acid-rinsed loaded carbon 57 a exits a discharge outlet 2028 .
- the acid-rinsed loaded carbon exiting the discharge outlet 2028 may be captured and contained by a holding tank 2060 and subsequently transported (via pump 2030 ) to a downstream process (e.g., aqueous rinse cycle).
- a downstream process e.g., aqueous rinse cycle
- the acid-rinsed loaded carbon exiting the discharge outlet 2028 may directly enter a downstream process (e.g., pour into another aqueous rinse tank 200 ′ without an intermediate holding tank 2060 and pump 2023 ).
- Holding tank 2060 advantageously serves as a buffer which maintains a level of process control and prevents too much carbon feed to downstream processes.
- replenished dilute acid solution 57 c ′ (obtained by filtering acid-rinsed loaded carbon 57 a with second screen 2036 ) enters recirculation tank 2039 and is pumped to chamber 2020 via a pump 2030 .
- the replenished dilute acid solution 57 c ′ enters the recirculation inlet 2023 a and then passes upwards through fluidized bed panel 2021 via nozzles 2011 .
- the replenished dilute acid solution 57 c ′ suspends incoming loaded/reloaded carbon 57 , and moves the loaded/reloaded carbon 57 through the chamber 2020 and around baffles 2011 for a predetermined residence time.
- the replenished dilute acid solution 57 c ′ passes through recycle screens 2008 and filtered dilute acid solution 57 c re-enters the recirculation tank 2039 via recirculation outlet 2033 b .
- Residence time of the loaded/reloaded carbon 57 may be increased or decreased by adjusting the inclination angle of the chamber 2020 and/or adjusting the angular orientation of nozzles 2011 .
- the inclination angle of chamber 2020 and angular positions of nozzles may be preset by the manufacturer and permanently fixed in the optimum configuration to yield the most efficient residence time for said process.
- a water-based, loaded carbon slurry 57 comprising approximately 30-300 oz/ton gold and approximately 30% wt/wt, activated coconut shell carbon is delivered to a continuous acid wash system 10 ′.
- the loaded active carbon is continuously transferred from the acid wash tank to an aqueous rinse tank 14 , 200 ′ where the loaded active carbon is fluidized and cleaned with water.
- the loaded carbon is subsequently continuously transferred from the aqueous rinse tank 14 , 200 ′ to a caustic rinse tank 16 , 200 ′′.
- the pH of the loaded active carbon delivered to the caustic rinse tank is raised above 10 by a caustic solution comprising approximately 1-3 wt % sodium hydroxide.
- the basic descaled loaded carbon 50 is fed continuously to a splash vessel 22 within a continuous elution system 20 ′ via a transfer medium of caustic strip solution comprising approximately 1 wt % caustic (NaOH) and 0.1 wt % cyanide (NaCN).
- the splash vessel 22 is generally held at an operating temperature between approximately 100 and 200 degrees Fahrenheit (° F.), and at a pressure of approximately atmospheric level.
- the loaded carbon is transferred from the splash vessel 22 to the continuous elution vessel 24 , where the gold is removed from the carbon (i.e., gold dissolution).
- the continuous elution vessel 24 operates at roughly 300 degrees Fahrenheit (° F.), which temperature is achievable by elevating the strip solution pressure to roughly 70 psi (gauge).
- the continuous elution vessel 24 continuously discharges into a lower pressure flash vessel 25 .
- a drop in pressure between the continuous elution vessel 24 and flash vessel 25 causes rapid flash vaporization of a portion of the effluent caustic strip solution.
- Steam generated is channeled to the splash vessel 22 , thereby simultaneously heating the splash vessel 22 and cooling the flash vessel 25 .
- Spent carbon (e.g., comprising less than 1 oz/ton gold), is continuously moved out of the continuous elution system 20 ′ and into a regeneration process 30 .
- the approximately 300° F. pressurized caustic strip solution is filtered by one or more screens or filters 324 to remove barren carbon particulate and form electrolyte solution 53 , which is then passed through a continuous electrolytic metal extraction (i.e., electrowinning) cell 42 .
- the electrolyte solution 53 is forced (via the increased pressure provided by the continuous elution vessel 24 ) through at least one channel 462 having a fixed helical path between a cylindrical sleeve anode 474 and a cylindrical sleeve cathode 472 .
- a voltage between approximately 2 and 4 volts is passed between the anode 474 through the electrolyte solution 53 and the cathode 472 , thereby depositing cathode sludge concentrate 53 f on surfaces of the cathode 472 .
- the velocity of the electrolyte solution 53 creates a forced flow electrolyte stream 53 b within the channel 462 which continuously washes the collected cathode sludge concentrate 53 f which may form and collect on the cathode's surfaces to the conical bottom of the cell 42 , where it may be removed at the operator's leisure or continuously via a control valve.
- a contractor or other entity may provide a system 100 ′ or process 100 for the continuous recover of metals in part or in whole as shown and described.
- the contractor may receive a bid request for a project related to designing a continuous metal recovery system 100 ′ or process 100 , or the contractor may offer to design such a system 100 ′ or a process 100 for a client.
- the contractor may then provide, for example, any one or more of the devices or features thereof shown and/or described in the embodiments discussed above.
- the contractor may provide such devices by selling those devices or by offering to sell those devices.
- the contractor may provide various embodiments that are sized, shaped, and/or otherwise configured to meet the design criteria of a particular client or customer.
- the contractor may subcontract the fabrication, delivery, sale, or installation of a component of the devices or of other devices used to provide such devices.
- the contractor may also survey a site and design or designate one or more storage areas for stacking the material used to manufacture the devices.
- the contractor may also maintain, modify, or upgrade the provided devices.
- the contractor may provide such maintenance or modifications by subcontracting such services or by directly providing those services or components needed for said maintenance or modifications, and in some cases, the contractor may modify an existing metal recovery process 9000 or system 9000 ′ with a “retrofit kit” to arrive at a modified process or system comprising one or more method steps, devices, or features of the systems 100 ′ and processes 100 discussed herein.
- particulates and carriers other than carbon e.g., polymers or ion exchange resins
- reagents other than water, cyanide, and caustic may be used to wash, descale, or strip the particulates.
- the disclosed systems and processes may be used to recover numerous types of materials including, but not limited to copper, gold, silver, platinum, uranium, lead, zinc, aluminum, chromium, cobalt, manganese, rare-earth and alkali metals, etc. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
Abstract
A system [100′] and process [100] for the continuous recovery of metals is disclosed. The system [100′] comprises a continuous acid wash system [10′], a holding tank [60], a continuous elution system [20′], a continuous electrowinning system [40′], a carbon regeneration system [30′], and a continuous carbon loading/adsorption system [70′]. The systems and methods disclosed overcome the disadvantages associated with current systems and processes which utilize batch process steps and equipment designed for batch processes. The systems [10′, 20′, 30′] are each configured to receive a continuous inflow of a solution or slurry and deliver a continuous outflow of a solution or slurry, without interruptions which are common with conventional metal recovery systems [9000′].
Description
- This invention relates to mining and metallurgical refining and more particularly to systems and processes for solvent extraction and electroextraction of metals.
- To this end, there are generally two main processes available for precious metal concentration and recovery: zinc precipitation, and electrowinning. Zinc precipitation involves crushing and grinding ore containing the precious metal (e.g., gold), and then combining the ground ore with a water and caustic cyanide solution. The resulting mud-like pulp is moved to a settling tank where the coarser gold-laden solids move to the bottom via gravity, and a lighter first pregnant solution of water, gold, and cyanide moves to the top and is removed for further processing. The gold-laden solids are agitated and aerated in a separate agitated leach process where oxygen reacts to leach the gold into the caustic water and cyanide forming a second pregnant solution. The second pregnant solution passes through a drum filter which further separates remaining solids. The first and second pregnant solutions are combined with zinc to precipitate out the dissolved gold. The resulting precipitated gold concentrate may then be smelted to produce refined gold bar.
- Electrowinning typically involves extracting a precious metal such as gold from an electrolyte. First, activated carbon is combined with a pregnant solution in a batch process step. The activated carbon adsorbs the precious metal contained within the pregnant solution, and becomes “loaded” with the precious metal. The loaded carbon is then descaled by sequentially washing it in three batch process steps to remove ore residue. First, the loaded carbon is moved to a washing tank and then the tank is filled with a dilute acid solution. The washing tank is then drained and the used dilute acid solution is pumped away and disposed of. The same washing tank is then filled with water to rinse remaining acid from the loaded carbon. The water becomes slightly acidic during this process. In a similar fashion to the dilute acid, the used slightly acidic rinse water is also drained from the washing tank, pumped away, and disposed of. Lastly, the tank is filled with a caustic solution, and the activated carbon is washed in the caustic solution. The used caustic solution is then drained from the tank, pumped away, and disposed of. An optional final water rinse step may be performed by again, filling the washing tank with rinse water or pH-neutral solution, rinsing caustic residue from the loaded carbon, and then draining the tank of the used rinse water/solution so that it may be pumped away for disposal.
- After washing, the loaded carbon is removed from the washing tank and then added to a strip solution comprising water, a caustic substance, and cyanide to form a strip solution/loaded carbon slurry. The strip solution/loaded carbon slurry goes through an elution process where high temperatures and pressures are used to “re-leach” gold from the loaded carbon into the caustic strip solution to form an electrolyte solution. The electrolyte solution is then moved to a batch electrolytic cell where wire (e.g., reticulated) or plate cathodes collect deposited gold concentrate during electrolysis. After the batch electrowinning process, the cathodes are manually removed from the cell for cleaning, so that gold concentrate deposited thereon can be removed from the cathodes and readied for smelting. After cleaning, the cathodes are then manually replaced within the electrolytic cell, and the entire sequence of batch washing, elution, and electrowinning processes is repeated. Some cathodes (e.g., wire cathodes, due to their small interstices) are not re-useable and must be recycled after processing, thereby increasing overhead/operational costs.
-
FIG. 27 schematically illustrates a conventionalmetal recovery process 9000 as described above. Activated or reactivatedcarbon 9560 is suspended within a pregnant solution in a conventional batchcarbon loading step 9700. The pregnant solution is generally formed by percolating a dilute cyanide solution through a heap leach pad of crushed mineral-laden ore (e.g., by way of a drip or spray irrigation having a concentration of about 0.5 to 1 pound of sodium cyanide, potassium cyanide, or calcium cyanide per ton of solution). Once the active carbon adsorbs the desired material (e.g., gold, silver, platinum, lead, copper, aluminum, platinum, uranium, cobalt, manganese) from the pregnant solution, it becomes “loaded”carbon 9570 and enters a batchacid wash process 9100 configured for descaling the loadedcarbon 9570 as previously discussed. -
FIG. 28 shows one example of a conventional batchacid washing system 9100′. Loadedcarbon 9570 enters anacid wash vessel 9120 which receives dilute acid from adilute acid tank 9140 via apump 9132. Dilute acid overflow is captured by asump pump 9150 which moves the overflow to a neutralizingtank 9160. Contents of the neutralizingtank 9160 may be moved to a secondary holding tank via apump 9136. The conventional batchacid wash process 9100 continues by draining theacid wash vessel 9120 of dilute acid solution, and then filling thevessel 9120 with an aqueous rinse solution. Overflow of aqueous rinse solution is captured bysump pump 9150 which moves the overflow to a neutralizingtank 9160 and/or a holding tank. Theprocess 9100 may continue by draining thevessel 9120 of aqueous rinse solution, and then filling thevessel 9120 with a caustic rinsing agent. Overflow of the caustic rinse may likewise be captured bysump pump 9150 and moved to a neutralizingtank 9160 and/or a holding tank (not shown). - After the loaded
carbon 9570 is descaled, it leaves the batch acid washing process 9100 (via carbon transfer pump 9134) and enters a conventional batch (e.g. Zadra strip)elution process 9200. As shown inFIG. 29 , a conventionalbatch elution process 9200 typically involves feeding descaled loadedcarbon 9500 and/or loaded carbon directly from anadsorption system 9700 into astrip vessel 9240.Strip vessel 9240 is generally a large cylindrical tank of material suitable for holding reagents at an elevated pressure and temperature (e.g., 138 degrees C.-148 degrees C.). The descaled loadedcarbon 9500 is maintained within thestrip vessel 9240 at high temperatures and pressure in the presence of a caustic aqueous strip solution comprising cyanide. After a period of time, spentcarbon 9550 is removed from the strip vessel 9240 (e.g., via carbon transfer pump 9232), and is moved to a carbon handling system orcarbon regeneration system 9300′ orprocess 9300. Hot electrolyte solution 9421 is formed within thestrip vessel 9240 as material previously adsorbed onto the loaded carbon leaches into the strip solution. The hot electrolyte solution 9421 is also removed from thestrip vessel 9240 and passes through a heating skid 9250 or equivalent heat exchanger for cooling before entering a conventionalbatch electrowinning system 9400′ orprocess 9400. Cooling of hot electrolyte solution 9421 to form a lowertemperature electrolyte solution 9530 is generally necessary to reduce the risk of flashing within a conventional batch electrolyticmetal recovery cell 9420. The heating skid 9250 also serves to recycle energy by warmingcooler barren solution 9540 which exits the electrolytic metal recovery cell 9420 (e.g., at about 66 degrees C.) and/orbarren solution 9237 which exits the barren solution storingtank 9220 before re-entering thestrip vessel 9240 to serve once again as a strip solution re-leaching agent. Warming of the coolerbarren solution hot barren solution 9239 may also be done using a heater in addition to, or in lieu of said heating skid 9250. One ormore pumps strip vessel 9240. Additional reagent from a reagent handling system and/or more pregnant solution may be added tobarren solution tank 9220 as needed. - As shown in
FIG. 30 ,electrolyte solution 9530 enters a conventional batch electrolyticmetal recovery cell 9420 which operates in batch cycles. A series of parallel plate cathodes are placed within close proximity and theelectrolyte solution 9530 is pumped in and agitated around the cathodes. Body portions of thecell 9420 carry an opposing charge with respect to the cathodes, and by virtue of electrolysis, ions contained in theelectrolyte solution 9530 are subsequently deposited on the cathodes as a cathode sludge concentrate of the recovery metal or as a solid cathode plating. In operation, cathodes are typically removed simultaneously from thecell 9420 in a batch process step in order to collect the recovered metal. In instances where plate cathodes are used, the cathode may be flexed to delaminate and remove the hard cathode plating from the cathode. In other instances where higher deposition wire mesh (i.e., “reticulated”) cathodes are employed, the concentrate is separated from the cathode in a subsequent process and the cathodes are then recycled. Sludge concentrate may collect at the bottom of thecell 9420 and may be removed periodically. Anelectrowinning pump box 9440 andpump 9430 may be employed to temporarily store spent electrolyte (i.e., barren solution) which is removed from thecell 9420 between batches. - Problems associated with the abovementioned conventional
acid wash systems 9100′ andprocesses 9100 are numerous. For instance, the systems utilize independent, non-continuous, “batch” process steps which require constant manpower, downtime, and energy (e.g, continually draining and refilling the sameacid wash vessel 9120 with different rinsing agents). Moreover, such conventional batchacid wash processes 9100 typically discard expensive acid, caustic, and/or other reagents after each use. This increases overhead (e.g., purchasing costs, disposal costs) and creates unnecessary harm to the environment. Furthermore, every time a conventionalacid wash vessel 9120 is drained and re-filled with a different rinsing solution, carbon (and precious minerals/metals attached thereto) may not be recovered due to system inefficiencies caused by heat, friction, increased pump residence time and exposure, an increased number of pipe elbows and valves, and the frequent discarding of spent rinsing solution which may still contain small amounts of loaded carbon and precious metal. In other instances (not shown), if separate vessels are used for each rinse step of the acid wash process, as many as four tanks and ten pumps may be required. This increases both initial plant overhead costs and overall plant footprint. - Problems associated with the described conventional
batch elution process 9200 are also numerous. For instance, theprocess 9200 employs batch process steps which require constant manpower and energy (e.g., continually draining and refilling thestrip vessel 9240 with new strip solution, hotbarren solution 9239, and loadedcarbon 9500 each timemore electrolyte solution 9530 is needed for electrowinning 9400). This increases overhead costs (e.g., labor, maintenance), complicates production scheduling, and may cause harm to the environment. Furthermore, conventionalmetal recovery systems 9000′ are bulky and require large plant layout footprints as demonstrated byFIG. 23 , when compared to asystem 100′ for the continuous recovery of metals according to the invention (FIG. 22 ) which will be described hereinafter. Moreover, conventional elution systems have limited operating flow rates, temperatures, and pressures which drive up radiation losses and power consumption. Additionally, the electroextraction of metals using the conventional “batch” electrowinning processes 9400 described above requires intervals of non-production downtime of theelectrowinning cell 9420 and significant physical labor, which may contribute to premature cathode wear and wastedelectrolyte solution 9530. - The process of using zinc to precipitate precious metals out of pregnant solutions is also costly, may be less efficient for large-scale operations, works for only certain metals, and may result in less precious metal recovery.
- It is, therefore, an object of the invention to provide an improved metal recovery system which is configured for continuous carbon loading/adsorption, continuous washing and stripping of loaded carbon, continuous electrolyte formation, continuous electrowinning, and continuous regeneration/re-activation, thereby avoiding the aforementioned problems associated with conventional batch metal recovery processes.
- Another object of the invention is to improve the efficiency of a metal recovery process (e.g., by minimizing radiation losses, reducing power consumption, minimizing reagent consumption, and preventing carbon breakdown and electrolyte loss).
- Yet another object of the invention is to prevent or minimize carbon loss and reagent waste.
- Another object of the invention is to maximize total metal recovery.
- Another object of the invention is to provide a metal recovery system which is configured to cost less and have a smaller footprint area than conventional metal recovery systems.
- Another object of the invention is to provide a system and process for the recovery of metals which is configured to operate at higher flow rates, temperatures, and/or pressures than conventional processes.
- Yet even another object of the invention is to reduce the percentage by weight of unrecovered metal present in spent electrolyte/barren solution.
- These and other objects of the invention will be apparent from the drawings and description herein. Although every object of the invention is believed to be attained by at least one embodiment of the invention, there is not necessarily any one embodiment of the invention that achieves all of the objects of the invention.
- A system for the continuous recovery of metals is provided. The system comprises, in accordance with some embodiments of the invention, at least one of a continuous acid wash system configured for receiving a continuous, uninterrupted inflow of loaded carbonaceous particulate and delivering a continuous, uninterrupted outflow of descaled loaded carbonaceous particulate; a continuous elution system configured for receiving a continuous, uninterrupted inflow of a strip solution containing a descaled loaded carbonaceous particulate and delivering a continuous, uninterrupted outflow of electrolyte solution; and a continuous electrowinning system configured for receiving a continuous, uninterrupted inflow of electrolyte solution, delivering a continuous uninterrupted outflow of a barren solution, and continuously and uninterruptedly forming a cathode sludge concentrate. Each of the continuous acid wash system, the continuous elution system, and the continuous electrowinning system are generally configured to operate simultaneously without periodic interruptions which are common with conventional batch metal recovery processes.
- In some embodiments, the system may comprise an integrated carbon regeneration system operatively connected to the continuous elution system. A continuous carbon loading/adsorpsion system may be operatively connected to and upstream of the continuous acid wash system. The continuous acid wash system may be operatively connected to the continuous elution system; for example, via a holding tank between said continuous acid wash system and said continuous elution system. One or more pumps may be provided to facilitate the transportation of slurry and solids within the system. In preferred embodiments, the continuous elution system is operatively connected to the continuous electrowinning system and comprises one or more screens or filters configured to prevent carbonaceous particulate from passing to the continuous electrowinning system.
- The continuous acid wash system may comprise a chamber adapted for retaining a fluidization medium; an inlet adapted for receiving a feed containing loaded carbonaceous particulate; a fluidized bed distribution panel or other means adapted for fluidizing the loaded carbonaceous particulate in the presence of said fluidization medium; an opening adapted to pass loaded carbonaceous particulate and fluidization medium from the chamber; and a screen adapted to filter loaded carbonaceous particulate from a fluidization medium. The continuous elution system may comprise a splash vessel, a continuous elution vessel, and a flash vessel, wherein the splash vessel is operatively connected to the continuous elution vessel in series, the continuous elution vessel is operatively connected to the flash vessel in series, and the splash vessel is operatively connected to the flash vessel in parallel. The continuous electrowinning system comprises an electrolytic cell having a cell body configured to maintain electrolyte solution at a high pressure and/or temperature; at least one anode; at least one cathode; an inlet configured for receiving a continuous, uninterrupted influent stream of electrolyte solution; a first outlet configured for discharging a continuous, uninterrupted effluent stream of spent electrolyte solution; a second outlet configured for removing cathode sludge concentrate; and a residence chamber configured to continuously transfer electrolyte solution from said inlet to said first outlet and increase residence time of said electrolyte solution between said at least one anode and said at least one cathode. The residence chamber may comprise one or more channels which are configured to provide a forced flow of electrolyte solution therein which is strong enough to continuously dislodge and/or transport cathode sludge concentrate along said one or more channels and eventually out of said residence chamber.
- The continuous elution vessel may comprise an influent manifold and an effluent manifold which communicate with the first outlet and inlet of the electrolytic cell, respectively, and may further comprise a fluidized bed and/or one or more internal baffles which are configured to torture flow paths and increase a residence time of loaded carbonaceous particulate therein. A valve configured to flash solution leaving the continuous elution vessel and entering the flash vessel may also be provided.
- The continuous acid wash system may comprise at least one of an acid solution, an aqueous solution, and a caustic solution. The continuous elution system may comprise a solution containing at least one of a carbonaceous particulate loaded with a precious metal, an electrolyte solution, spent carbonaceous particulate, a caustic, an aqueous component, and cyanide. The continuous electrowinning system may comprise an electrolyte solution or cathode sludge concentrate. Each of the continuous acid wash system, the continuous elution system, and the continuous electrowinning system may be configured to increase a residence time, pressure, or temperature of solutions or slurries contained therein and may comprise a screen or filter element.
- In some embodiments, the continuous acid wash system may comprise multiple washing vessels, each washing vessel comprising a chamber adapted for retaining a fluidization medium; an inlet adapted for receiving a feed containing a loaded carbonaceous particulate; a fluidized bed distribution panel or other means adapted for fluidizing and cleaning the loaded carbonaceous particulate with said fluidization medium; an opening adapted to pass loaded carbonaceous particulate and fluidization medium from the chamber; and a screen adapted to filter loaded carbonaceous particulate from fluidization medium. For instance, in some embodiments, the continuous acid wash system may comprise an acid wash tank containing an acidic fluidization medium, an aqueous rinse tank containing a substantially pH-neutral aqueous solution, and a caustic rinse tank containing an alkaline fluidization medium.
- In some embodiments, the continuous acid wash system may comprise one or more recirculation tanks for collecting spent fluidization medium, and one or more weirs, channels, valves, or drains for capturing spent fluidization medium. The continuous electrowinning system may be configured for continuous and uninterrupted collection and removal of said cathode sludge concentrate and may comprise one or more channels defined between a cathode, an anode, and an insulator. The one or more channels may comprise portions of a helix, spiral, coil, compound curve, 3D-spline curve, figure-8, or serpentine shape and the cathode and anode may be formed as sleeves or tubes which are separated by said insulator. In some embodiments, the carbon regeneration system is operatively connected to both the continuous elution system and the continuous carbon loading/adsorpsion system, and the continuous carbon loading/adsorpsion system is operatively connected to said continuous acid wash system.
- A process for the continuous recovery of a metal is also disclosed. The process, comprises, in accordance with some embodiments, continuously feeding a continuous wash system with particulate loaded with a metal; continuously washing said loaded particulate within the continuous wash system to descale the loaded particulate; continuously removing descaled loaded particulate from said continuous wash system; continuously loading a continuous elution system with said descaled loaded particulate; continuously removing electrolyte solution from said continuous elution system; continuously feeding a continuous electrowinning system with said electrolyte solution; continuously removing spent electrolyte solution from said continuous electrowinning system; and, continuously delivering said spent electrolyte solution to said continuous elution system; wherein each of the continuous wash system, the continuous elution system, and the continuous electrowinning system are configured to allow the above steps to be performed simultaneously, without the periodic interruptions required for conventional batch processes.
- The process may further comprise continuously removing spent particulate from the continuous elution system; continuously feeding said spent particulate to a carbon regeneration system; continuously removing cathode sludge concentrate from the continuous electrowinning system; and/or forming said loaded particulate by continuously adsorbing metal onto said particulate in a continuous carbon loading/adsorption system which is similar to or identical to said continuous wash system. The particulate may be one of a carbonaceous particulate, a polymeric adsorbent, or an ion-exchange resin.
-
FIGS. 1 and 2 schematically illustrate a system and method for the continuous recovery of metals according to some embodiments; -
FIG. 3 is a flowchart of a three-sequence continuous acid wash operation according to some embodiments; -
FIGS. 4 and 5 outline steps of a continuous acid washing process according to some embodiments; -
FIGS. 6 and 7 depict a washing tank which may be used in the acid wash process shown inFIGS. 1-5 ; -
FIG. 8 shows an acid wash system comprising a plurality of the washing tanks depicted inFIGS. 6 and 7 ; -
FIGS. 9 and 12 schematically illustrate a system and method of continuous elution according to some embodiments; -
FIG. 10 is an isometric view of a continuous elution system according to some embodiments; -
FIG. 11 shows a side cutaway view of the continuous elution system ofFIG. 10 ;FIGS. 13 and 19 schematically illustrate a system and method of continuous electrowinning according to some embodiments; -
FIG. 14 shows a top plan view of a continuous electrowinning system according to some embodiments; -
FIGS. 15 and 16 are vertical and isometric cutaway views, respectively, of a continuous electrowinning system taken on line XV-XV inFIG. 14 ; -
FIG. 17 is a detailed view ofFIG. 15 , showing the particulars of an inlet according to some embodiments; -
FIG. 18 is a transverse cutaway view of an electrowinning cell along line XVIII-XVIII inFIG. 14 ; -
FIG. 20 shows a process for regenerating/reactivating spent carbon according to some embodiments; -
FIGS. 21 and 22 show a system for the continuous recovery of metals; -
FIG. 23 shows a conventional batch system for the recovery of metals; -
FIG. 24 shows an alternative to the washing tank shown inFIGS. 6-8 or an apparatus to be used for continuous carbon loading/adsorption; -
FIG. 25 shows a detailed isometric view of the chamber shown inFIG. 24 ; -
FIG. 26 is a cutaway view of the chamber shown inFIG. 25 ; -
FIG. 27 shows a conventional system for the recovery of metals. -
FIG. 28 shows a conventional acid wash process; -
FIG. 29 shows a conventional batch elution process; and, -
FIG. 30 shows a conventional batch electrowinning process. - As shown in
FIGS. 1 and 2 , aplant system 100′ orprocess 100 for the continuous recovery of a metal from mined ore may comprise, in accordance with some embodiments of the invention, a continuousacid wash system 10′ orprocess 10, acontinuous elution system 20′ orprocess 20, acontinuous electrowinning system 40′ orprocess 40, a continuouscarbon regeneration system 30′ orprocess 30, and a continuous carbon loading/adsorption system 70′ orprocess 70. Activated/reactivated carbon 56 (which may be derived for example, from coconut shells or charcoal), or alternatively, an equivalent particulate substance such as loaded polymeric adsorbent or loaded ion-exchange resin, is subjected to a continuouscarbon adsorption process 70 where it spends a time of residence suspended in a pregnant solution which contains a dissolved target recovery metal such as gold, silver, copper, aluminum, platinum, uranium, chromium, zinc, cobalt, manganese, or lead. The continuous carbon loading/adsorption system 70′ orprocess 70 may comprise, for example, an apparatus as shown inFIGS. 6 and 7 orFIGS. 24-26 which serves to fluidize the activated/reactivatedcarbon 56 within the pregnant solution. Once thecarbon 56 becomes loaded with the target recovery metal, it undergoes a continuousacid wash process 10. Descaled loadedcarbon 50 leaving the continuousacid wash process 10 enters a holdingtank 60 filled with a strip solution containing one or more reagents (e.g., water, caustic, and cyanide) to form aslurry 51 of strip solution and descaled loadedcarbon 50. Theslurry 51 enters acontinuous elution process 20 where the temperature and/or the pressure of theslurry 51 is increased and the target recovery metal previously adsorbed by the carbon is re-leached into the strip solution thereby forming anelectrolyte solution 53 which may be used for acontinuous electrowinning process 40. Barren solution (i.e., spent electrolyte) 54 leaving thecontinuous electrowinning process 40 is returned to thecontinuous elution process 20 and/or the holdingtank 60 for re-use. Asolids fraction 55 of spent carbon, depleted of its target recovery metal via thecontinuous elution process 20, moves to acarbon regeneration process 30 for reactivation before being re-used in the continuous carbon loading/adsorption process 70. - As shown in
FIGS. 2-5 , a continuousacid wash process 10 may generally comprise the steps of: feeding 1004 loadedcarbon 57 into a continuousacid wash system 10′, fluidizing 1006 incoming loadedcarbon 57 in a dilute acid solution within a firstacid wash tank 12, extracting 1008 loaded carbon from theacid wash tank 12,screening 1010 the extracted loaded carbon to remove the dilute acid solution, capturing 1012dilute acid solution 57 c separated from the loaded carbon, optionally processing 1014 the captureddilute acid solution 57 c (e.g., filtering, additives, pH adjust), and recycling thedilute acid solution 57 c by feeding 1016 thedilute acid solution 57 c back into theacid wash tank 12. Acid-rinsed loadedcarbon 57 a which has undergone an acid bath inacid wash tank 12 is fed 1018 into a second aqueous rinsetank 14 containing water or another pH-neutral aqueous rinsesolution 57 d, and then fluidized 1020 in said aqueous rinsetank 14. Theprocess 10 further comprises extracting 1022 rinsed loadedcarbon 57 b from the aqueous rinsetank 14,screening 1024 the extracted rinsed loadedcarbon 57 b to remove aqueous rinsesolution 57 d, capturing 1026 separated aqueous rinsesolution 57 d separated from the rinsed loadedcarbon 57 b, optionally processing 1028 the captured aqueous rinsesolution 57 d (e.g., filtering, additives, pH adjust), and recycling the aqueous rinsesolution 57 d by feeding 1030 the aqueous rinsesolution 57 d back into the aqueous rinsetank 14. Rinsed loadedcarbon 57 b which has undergone washing in aqueous rinsetank 14 is fed 1032 into a third caustic rinsetank 16 containing a caustic rinsesolution 57 e, and is then fluidized 1034 in said caustic rinsetank 16. The continuousacid wash process 10 further comprises extracting 1036 descaled loadedcarbon 50 from the caustic rinsetank 16,screening 1038 the extracted descaled loadedcarbon 50 to remove caustic rinsesolution 57 e, capturing 1040 caustic rinsesolution 57 e separated from the descaled loadedcarbon 50, optionally processing 1042 the captured caustic rinsesolution 57 e (e.g., by filtering, providing additives, or adjusting pH), and recycling the caustic rinsesolution 57 e by feeding 1044 thesolution 57 e back into the caustic rinsetank 16. The continuousacid wash process 10 may comprise the step of providing one ormore pumps 13 a, 13 b for re-circulating the rinsing solutions in each of theaforementioned tanks - Turning now to
FIGS. 6 and 7 , anacid wash tank 200 for cleaning and descaling a loaded particulate material may be employed for any portion of the continuousacid wash process 10. The loaded particulate material washed within saidacid wash tank 200 may be of any particle size, shape, and density which can be fluidized by or suspended within a cleaning fluidization medium. Theacid wash tank 200 is advantageously configured to descale active carbon particulate which has been loaded with a target metal, in preparation for creating an electrolyte for electrowinning. In such instances, theacid wash tank 200 may be filled with a fluidization medium comprising acid.Similar tanks 200′, 200″ may be used with fluidization mediums comprising water or caustic soda. Moreover, similar tanks may be used in yet other processes such as a continuous carbon loading/absorption process 70, wherein the particulate comprises activated/reactivatedcarbon 56, and the fluidization medium comprises a pregnant solution formed by percolating cyanide and/or other reagents through a heap leach pad of crushed ore containing a target metal or mineral. - According to some embodiments,
acid wash tank 200 may comprise an acid wash tank having afirst chamber 220, a first fluidizedbed distribution panel 221, afirst inlet 222, afirst recirculation inlet 223 a, afirst recirculation outlet 223 b, afirst weir 224, afirst screen 226, afirst overflow outlet 227, afirst discharge outlet 228, afirst recirculation tank 229, abottom wall 260, an innertubular wall 266, an outertubular wall 268, and afirst channel 282 defined between the innertubular wall 266 and outertubular wall 268 adjacent thefirst weir 224. Thefirst screen 226 serves to filter an incoming feed by separating its liquid fraction (e.g., spent pregnant solution, fluidization medium, or transport fluid) from its solid particulate fraction (metal-laden loaded or reloaded carbon). The liquid fraction drained from the particulate is maintained in thefirst recirculation tank 229 and may be removed throughfirst recirculation outlet 223 b. Thefirst recirculation outlet 223 b may be sealed during operation, coupled to a holding tank, coupled to a drain, coupled to a sump pump, or otherwise configured to feed an upstream or downstream process. - In some embodiments, as shown in
FIG. 8 , a continuousacid wash system 10′ may comprise one or moreseparate washing tanks tanks first tank 200 may comprise an acid wash tank containing a strong ordilute acid solution 57 c, whereas second 200′ and third 200″ tanks may comprise aqueous and caustic rinsing tanks containing aqueous 57 d and caustic 57 e rinsing agents, respectively. While not required,tanks tanks tanks tank 2000 as shown inFIGS. 24-26 , which will be described hereinafter. - A first fluidization medium comprising a dilute acid or anti-scaling agent solution may occupy the first
acid wash tank 200. In some embodiments, the first fluidization medium may comprise a solution of 1-10% vol/vol mineral acid, such as nitric acid or hydrochloric acid configured to dissolve carbonate scale. In use, incoming loaded/reloadedcarbon 57 moves over thefirst screen 226 and flows into thefirst chamber 220 of the firstacid wash tank 200 via thefirst inlet 222. Fluid which may be present with the incoming loaded/reloadedcarbon 57 is drained and enters thefirst recirculation tank 229. The screened loaded carbon subsequently falls downwardly along thefirst screen 226 and towards the first fluidizedbed distribution panel 221 and is fluidized by the first fluidization medium. The first fluidization medium enters thefirst recirculation inlet 223 a and passes throughdistribution panel 221. Clarified first fluidization medium rises above the highest suspended level of loaded carbon within the firstacid wash tank 200 and pours over thefirst weir 224 and into thefirst channel 282. Thereafter, clarified first fluidization medium exits the firstacid wash tank 200 viaoutlet 227 and optionally feeds thefirst recirculation inlet 223 a and first fluidizedbed distribution panel 221. One or more pumps 13 a may be provided betweenoutlet 227 andinlet 223 a. - A slurry of acid-rinsed loaded
carbon 57 a and residual first fluidization medium exits the firstacid wash tank 200 through thefirst discharge opening 228 and enters a second aqueous rinsetank 200′ through asecond inlet 232. The acid-rinsed loadedcarbon 57 a may be conveyed to thetank 200′ using only gravitational forces, or the acid-rinsed loadedcarbon 57 a may be conveyed to thetank 200′ using one or more slurry pumps (not shown). A second fluidization medium such as a substantially pH-neutral aqueous scrubbing solution or a hot water may occupy the second aqueous rinsetank 200′. In use, the acid-rinsed loadedcarbon 57 a and first fluidization medium moves over asecond screen 236 or equivalent filter and then flows into thesecond chamber 230 for pre-soak. Thesecond screen 236 serves to separate residual first fluidization medium liquid from the acid-rinsed loadedcarbon 57 a, wherein drained first fluidization medium is maintained in asecond recirculation tank 239 and may be removed through second recirculation outlet. Thesecond recirculation outlet 233 b may be coupled to a holding tank, a filtering apparatus, or an upstream or downstream process. For instance, as schematically indicated by the dotted line path ofdilute acid solution 57 c′, thesecond recirculation outlet 233 b may be operatively connected to thefirst recirculation inlet 223 a to fluidize loaded/reloadedcarbon 57 within thefirst washing tank 200. Though not shown, one or more pumps may be disposed between theoutlet 233 b andinlet 223 a. - After passing over the
second screen 236, acid-rinsed loadedcarbon 57 a subsequently falls towards a second fluidizedbed distribution panel 231 and is fluidized within thesecond chamber 230 by a flow of second fluidization medium entering thesecond recirculation inlet 233 a and passing upwards throughpanel 231. Clarified second fluidization medium free of loaded carbon particulate rises above a suspended level of acid-washed loaded carbon and pours over asecond weir 234 and into asecond channel 284, where it exits the second aqueous rinsetank 200′ viaoutlet 237 and optionally feeds thesecond recirculation inlet 233 a and second fluidizedbed distribution panel 231 as schematically illustrated by dotted line path taken by aqueous rinsesolution 57 d. - A slurry of rinsed loaded
carbon 57 b and second fluidization medium exits thesecond washing tank 200′ through second discharge opening 238 and enters athird washing tank 200″ through athird inlet 242. The rinsed loadedcarbon 57 b may be conveyed to the third caustic rinsetank 200″ using only gravitational forces, or the rinsed loadedcarbon 57 b may be conveyed to thetank 200″ using one or more pumps (not shown). A third fluidization medium such as a caustic rinse solution may occupy thethird washing tank 200″. For example, the third fluidization medium may comprise an amount of sodium hydroxide (NaOH) or potassium hydroxide (KOH) between 0.5% and 5% wt, for instance 1% wt. The third fluidization medium may comprise other reagents, for instance 1-10% wt sodium cyanide (NaCN). The third fluidization medium may be heated (e.g., 20-100 degrees C.). In use, a slurry of rinsed loadedcarbon 57 b and second fluidization medium flows over athird screen 246 or equivalent filter and into thethird chamber 240. Thethird screen 246 serves to filter the slurry by separating its second fluidization medium liquid fraction from its rinsed loadedcarbon 57 b solid fraction. The separated second fluidization medium is maintained in athird recirculation tank 249. The second fluidization medium may be removed from thetank 249 via athird recirculation outlet 243 b which may be coupled to a holding tank, filtering apparatus, or one or more upstream or downstream processes. For instance, as schematically indicated by path taken by aqueous rinsesolution 57 d′, thethird recirculation outlet 243 b may be operatively connected to thesecond recirculation inlet 233 a in order to help fluidize particulate within thesecond washing tank 200′. Though not shown, one or more pumps may be disposed between theoutlet 243 b andinlet 233 a. In some instances,outlet 243 b andinlet 233 a may be operatively connected to a plant water system. - After passing over
third screen 246, twice-rinsed loaded carbon particulate subsequently falls towards a third fluidizedbed distribution panel 241 and is fluidized within thethird chamber 240 by a flow of third fluidization medium entering thethird recirculation inlet 243 a and passing through thepanel 241. Clarified third fluidization medium rises above the highest level of suspension of the loaded carbon fluidized within thetank 200″ and pours over athird weir 244 and into athird channel 286, where it exits the caustic rinsetank 200″ viaoutlet 247 and optionally feeds thethird recirculation inlet 243 a as indicated by the dotted line path taken by caustic rinsesolution 57 e. - A slurry of caustic-rinsed, descaled loaded
carbon 50 and third fluidization medium exits the third caustic rinsetank 200″ through third discharge opening 248 and may be subsequently screened or filtered for further processing. After leaving thetank 200″, de-scaled loadedcarbon 50 within the slurry may be separated from the third fluidization medium liquid fraction by a screen or filter (not shown) and then added to a strip solution of water, caustic, and cyanide in aholding tank 60 for use in downstreamcontinuous elution 20 andelectrowinning 40 processes. - The continuous
acid wash system 10′ shown and described, when used, reduces or eliminates the need to continually purchase and replace lost quantities of carbon particulate, water, caustic, acid, and/or other anti-scaling agents.System 10′ also significantly reduces the amount of spent solution and carbon requiring disposal and reduces the potential for environmental harm. - It should be known that the particular features and suggested uses of the continuous
acid wash system 10′ described herein are exemplary in nature and should not limit the scope of the invention. For example,fluidized bed portions chambers system 10′ may be greater or less than what is shown. In some embodiments, the relative sizes, dimensions and/or volumes ofchambers chambers more tanks tank 200″ of asystem 10′ may be directly or indirectly coupled to a plurality of upstream aqueous rinsetanks 200′.Multiple tanks 200 may replace any one of thesingle tanks system 10′ by splittinginlets outlets chamber system 10′ or portions thereof may be used to continuously load activated carbon in a continuous carbon loading/adsorption process 70. For example, infeed particulate may comprise activated or reactivated carbon and the first, second, and third fluidization mediums may comprise a pregnant solution (e.g., sodium cyanide (NaCN) solution containing a dissolved precious metal). -
FIG. 9 illustrates acontinuous elution process 20 according to some embodiments. Afeed slurry 51 of strip solution and descaled loadedcarbon 50 is moved to asplash vessel 22 via gravity or one or more pumps 23. Thesplash vessel 22 increases the temperature and/or pressure ofincoming slurry 51 and delivers the hotpressurized slurry 51 a to acontinuous elution vessel 24. In thecontinuous elution vessel 24, target metal previously adsorbed onto the loaded carbon is leached into the strip solution to form anelectrolyte solution 53. Theelectrolyte solution 53 is filtered by one or more screens to remove spent carbon and non-stripped loaded carbon from theelectrolyte solution 53, before it is moved to acontinuous electrowinning process 40.Electrolyte solution 53 may be conveyed to the continuous electrowinning process via aneffluent manifold 28 b provided on thecontinuous elution vessel 24.Spent slurry 51 c of strip solution and spent carbon is flashed by avalve 29 and enters into aflash vessel 25 where steam is captured and returned to thesplash vessel 22 via asteam return 21 to help heat and pressurize thesplash vessel 22 in an efficient manner. The resulting concentrated spentslurry 51 d is separated into solid 55 and liquid 52 fractions using adewatering screen 26. Theliquid fraction 52 of concentrated spentslurry 51 d may be returned to holdingtank 60, and thesolids fraction 55 of the concentrated spentslurry 51 d (i.e., spent de-watered carbon) may be sent to acarbon regeneration process 30 for reactivation.Barren solution 54 returning from acontinuous electrowinning process 40 is generally heated with animmersion heater 27 and then sent back to thecontinuous elution vessel 24 via one ormore pumps 23 and aninfluent manifold 28 a. -
FIG. 10 shows acontinuous elution system 20′ according to some embodiments. Thecontinuous elution system 20′ generally comprises afirst splash vessel 22, a secondcontinuous elution vessel 24, and athird flash vessel 25 connected in series via piping sections, and asteam return 21 extending between thesplash 22 andflash 25 vessels in parallel. One ormore pumps 23 may be provided at various portions of thesystem 20′ in order to facilitate flows to, from, and between thevessels system 20′, and/orother portions 10′, 30′, 40′ within asystem 100′ for the continuous recovery of metals. - As shown in
FIG. 11 , thecontinuous elution vessel 24 comprises a fluidizedbed distribution panel 320 which separates aresidence chamber 340 from a fluidizingchamber 350. One ormore baffles 318 may be provided within theresidence chamber 340 in various configurations (e.g., number, angle, spacing, geometry), in order to increase the residence time of incoming hotpressurized slurry 51 a within thecontinuous elution vessel 24. The one ormore baffles 318 may be parallel and staggered to create aserpentine flow path 51 b of hotpressurized slurry 51 a. Thebaffles 318 may be parallel, non-parallel, staggered at a single predetermined angle, or disposed in alternating fashion with each baffle oriented in a different predetermined angle. It should be understood that other baffle patterns and arrangements may be used without limitation, and that the shapes, porosities, and/or textures ofbaffles 318 may differ from what is shown. For example, any one or more of thebaffles 318 may comprise folds, bends, curves, corrugations, openings, lattice structures, or the like. - Slurry flowing within the
continuous elution vessel 24 may contain incoming hotpressurized slurry 51 a andbarren solution 54 leaving acontinuous electrowinning system 40′ orprocess 40. Fluidizingchamber 350 may be fed by aninfluent manifold 28 a connected to thecontinuous elution vessel 24 via one or moreinfluent ports 326 having influent port mounts 322. Alternatively, theinfluent manifold 28 a may instead be connected directly to the one or more sidewalls 310 of thecontinuous elution vessel 24. A stream ofbarren solution 54 flows into thecontinuous elution vessel 24 via theinfluent manifold 28 a. The stream enters and fills the fluidizingchamber 350 and flows throughfluidized bed 320 to help fluidize and suspend carbon particulate within theresidence chamber 340 as it travels along theserpentine flow path 51 b. - An
effluent manifold 28 b is also provided to thecontinuous elution vessel 24 to extract anelectrolyte solution 53 from theresidence chamber 340 and deliver saidelectrolyte solution 53 to acontinuous electrowinning system 40′ orprocess 40.Effluent manifold 28 b comprises one or more effluent manifold ports, which may be provided with effluent manifold port mounts for ease of connection to thecontinuous elution vessel 24. Similarly to theinfluent manifold 28 a, theeffluent manifold 28 b may be connected directly to the one or more sidewalls 310 of thecontinuous elution vessel 24, or may be connected to thevessel 24 via one or moreeffluent ports 316 having effluent port mounts 312. - While in the
residence chamber 340 of thecontinuous elution vessel 24, loaded carbon is exposed to strip solution reagents under high temperature and high pressure conditions. The reagents in the strip solution act to strip the loaded carbon of its previously adsorbed metal contents (e.g., gold), and “re-leach” it into the solution to form an electrolyte solution. One or more screens orfilters 324 may be provided between theresidence chamber 340 and theeffluent manifold 28 b in order to extract a clarified stream ofelectrolyte solution 53 from thecontinuous elution vessel 24 and/or prevent carbon particulate from passing downstream of theeffluent manifold 28 b. In some embodiments, as shown, the placement of said screens orfilters 324 may be at the interface between the effluent ports and the one or more sidewalls 310 of thecontinuous elution vessel 24. However, the screens orfilters 324 may be provided in other locations without limitation, for instance: within theeffluent manifold 28 b, within thecontinuous elution vessel 24, at the interface between theeffluent manifold 28 b and mounts 312, or downstream of saideffluent manifold 28 b. It should be known that one or more seals or gaskets (not shown) may be placed between the influent 28 a oreffluent 28 b manifolds and thecontinuous elution vessel 24. - Fluidized carbon and solution within
residence chamber 340 continues to move along theserpentine flow path 51 b until it is either removed througheffluent manifold 28 b to be used as electrolyte, or passes throughoutlet 328. Theoutlet 328 may comprise an outlet mount 330 and/or anoutlet seal 329 for connecting to avalve 29. Thevalve 29 may be of any sort known in the art, such as a ball or cone valve without limitation, and one would appreciate that the valve may be separately coupled to, or formed integrally with either one or both of thecontinuous elution vessel 24 and theflash vessel 25. Moreover, additional piping sections may be added between thesecond outlet 328 and thevalve 29 if the distance between thecontinuous elution vessel 24 and theflash vessel 25 is large. - The stream of hot pressurized spent
slurry 51 c exiting thecontinuous elution vessel 24 “flashes” as it passes through thevalve 29. The resulting mixture of gas vapors, fluids, and solids enters the lowerpressure flash vessel 25, where heated steam is diverted back to thesplash vessel 22 via steam return piping 21. Unvaporized spent solution and spent carbon leave theflash vessel 25 in a stream of concentrated spentslurry 51 d. The concentrated spentslurry 51 d may comprise a barren solutionliquid fraction 52, and asolids fraction 55 of spent carbon substantially-free of previously-adsorbed precious metal (e.g., gold). As previously mentioned, the stream of concentrated spentslurry 51 d may be subsequently screened or filtered by adewatering screen 26. - In the embodiment shown, a
liquid fraction 52 of the concentrated spentslurry 51 d is separated from thesolid fraction 55 by dewateringscreen 26 and returned to the holdingtank 60 for re-use as strip solution. One or more pumps (not shown) may be provided to move theliquid fraction 52 to the holdingtank 60. Thesolids fraction 55 of dewatered spent carbon is sent to acarbon regeneration process 30 comprising aregeneration kiln 35 or other means for reactivating the carbon. Dewateringscreen 26 may be provided as a two-stage screen, wherein a first stage removes a majority of theliquid fraction 52 from the spentcarbon solids fraction 55, and a second stage removes residual caustic and/or cyanide from thesolids fraction 55 of spent carbon before it enters aregeneration kiln 35 or wash vessel. Accordingly, equipment in thecarbon regeneration system 30′ is not damaged. -
FIG. 12 schematically illustrates acontinuous elution process 20 according to some embodiments. First, aslurry 51 of descaled loadedcarbon 50 and a caustic strip solution comprising water and cyanide is produced 1048. Theslurry 51 may be formed and stored in aholding tank 60. Theslurry 51 is then pumped 1050 into thesplash vessel 22 which is configured to elevate the temperature and/or pressure of the descaled loaded carbon/strip solution slurry 51. After increasing the temperature and/orpressure 1052 of theslurry 51 in thesplash vessel 22, a hotpressurized slurry 51 a of loaded carbon/strip solution is formed and moved 1054 from thesplash vessel 22 to thecontinuous elution vessel 24. The hotpressurized slurry 51 a is kept within thevessel 24 for an increasedresidence time 1056, for instance, by providing afluidized bed 320 alone or in combination with a plurality ofbaffles 318 in order to elongate the physical travel path of the hotpressurized slurry 51 a between theinlet 304 of thevessel 24 and theoutlet 328. The physical travel path may be for instance, aserpentine flow path 51 b as shown. - During its time of residence within the
continuous elution vessel 24, the loaded carbon in the hotpressurized slurry 51 a is stripped of its adsorbed precious metal by reagents in the caustic strip solution. Accordingly, the caustic strip solution dissolves the precious metal into itself thereby forming anelectrolyte solution 53. Theelectrolyte solution 53 is screened to remove carbon particulate therefrom and is extracted 1064 from thecontinuous elution vessel 24. Subsequently, theelectrolyte solution 53 is fed 1066 to acontinuous electrowinning system 40′ (e.g., into a continuous electrolytic metal extraction cell 42) for precious metal recovery. During the electrowinning process 1068 (seeFIG. 19 ),barren solution 54 is continuously removed 1070 from thecontinuous electrowinning system 40′ and pumped 1072 back into thecontinuous elution vessel 24 either directly, or indirectly (e.g., via a barren solution holding tank (not shown) or immersion heater 27). - Solution and carbon are continuously removed from the
continuous elution vessel 24, and the liquid fraction of the solution “flashed” or at least partially vaporized 1058 with avalve 29 before entering theflash vessel 25. Theprocess 20 further comprises recovering 1060 heated steam from the rapid evaporation of exiting spentslurry 51 c, and piping 1062 the steam back to thesplash vessel 22 in order to efficiently increase 1052 the temperature and/or pressure of thefirst vessel 22. Concentrated spentslurry 51 d is removed 1074 from theflash vessel 25, and then dewatered 1076 to separate the spentliquid fraction 52 from the spentsolids fraction 55. Thesolids fraction 55 comprises dewatered carbon which is sent 1078 to acarbon regeneration system 30′, and the spentliquid fraction 52 of the concentrated spentslurry 51 d is sent 1080 to the holdingtank 60 for re-use. - It should be known that the particular features and suggested uses of the
continuous elution systems 20′ and processes 20 shown and described herein are exemplary in nature and should not limit the scope of the invention. For example,fluidized bed 320 may be replaced with, or used in combination with one or more mechanical agitators (not shown) to suspend loaded carbon particulate. Moreover, the number ofbaffles 318 in thecontinuous elution vessel 24 may be greater or less than what is shown, in order to provide the residence times and flow rates required for a particular process. Additionally, one or moreadditional vessels continuous elution system 20′ and placed in series or parallel withother vessels continuous elution vessels 24 may be directly or indirectly coupled to each other in parallel, and placed in series between asingle splash vessel 22 and asingle flash vessel 25. -
FIG. 13 shows acontinuous electrowinning process 40 according to some embodiments. Theprocess 40 comprises continuously providing anelectrolyte solution 53, continuously feeding theelectrolyte solution 53 to a continuous electrolyticmetal extraction cell 42, extracting cathode sludge concentrate 53 f from thecell 42 in asludge removal stream 53 g, continuously extractingbarren solution 54 from thecell 42 and using saidbarren solution 54 to feed acontinuous elution vessel 24 within acontinuous elution process 20. - As shown in
FIGS. 14-18 , thecontinuous electrowinning system 40′ largely comprises a continuous electrolyticmetal extraction cell 42 comprising acell body 406 having afirst end 440, asecond end 480, one or more sidewalls 482 extending therebetween, abase 404 having one ormore mounts 402, at least oneinlet 410 for receiving a continuous influent stream of a precious metal-containingelectrolyte solution 53, at least onefirst outlet 420 for providing continuous egress of a spentelectrolyte stream 53 d andbarren solution 54 contained therein, and at least onesecond outlet 430 for providing egress of cathode sludge concentrate 53 f collected within thecell 42. Thesecond outlet 430 may be configured for continuous egress of collected cathode sludge concentrate 53 f, or thesecond outlet 430 may be configured for intermittent egress of said collected cathode sludge concentrate 53 f. Within thecell body 406 is provided afirst chamber 405, asecond chamber 407, athird chamber 408, and aresidence chamber 460 comprising one or moreelongated channels 462. Thechannels 462 are configured to increase residence time of theelectrolyte solution 53 and provide a forcedflow electrolyte stream 53 b ofelectrolyte solution 53 therein which is strong enough to dislodge and/or displace cathodic sludge concentrate which forms and builds up within thechannels 462. The one ormore channels 462 may comprise, for example, a portion of a helix, double-helix, coil, spiral, serpentine, spline, compound curve, and may extend in curvilinear paths. In some embodiments, as shown, theresidence chamber 460 may be concentrically situated between thefirst chamber 405 and thethird chamber 408. Thefirst chamber 405 may be configured to be devoid of electrolyte and/or cathodic sludge concentrate during operation, and may generally serve as a space-filler bounded betweenfirst end 440,inner anode 477, andbaffle 450. The space fillingfirst chamber 405 generally provideschannels 462 within theresidence chamber 460 with a larger radius, thereby increasing the overall effective length and total surface area of thechannels 462 exposed to forced flow electrolyte streams 53 b contained therewithin. Thethird chamber 408 serves to temporarily hold and/or transport spentelectrolyte streams 53 d from within thecell 42 to one or morefirst outlets 420. In some embodiments, to reduce material costs, thefirst end 440 may be configured as an annular panel having a central opening exposing thefirst chamber 405, rather than as a solid continuous circular panel as shown. The one or morefirst outlets 420 may be provided at an upper portion of thecell 42 where overflow is likely to be more clarified and free from cathode sludge concentrate. - Each
channel 462 may be defined between at least oneanode 474, at least onecathode 472, and one ormore insulators 476 extending therebetween. In the particular embodiment shown, one ormore anodes 474 and one ormore cathodes 472 are provided as sleeve portions which alternate concentrically between anouter anode 479 and aninner anode 477 with each sleeve portion having a different radius. Theanodes 474 andcathodes 472 are radially separated and maintain a uniform spacing by one or more spacing protuberances 473 projecting from said one ormore cathodes 472. It should be understood, that while not shown, the one or more protuberances 473 may alternatively extend from theanodes 474 alone, or may extend from bothanodes 474 andcathodes 472 without limitation. However, by providing protuberances 473 on the one ormore cathodes 472, a small amount of extra cathodic surface area is provided for precipitating cathodic sludge concentrate out of the forcedflow electrolyte stream 53 b during electrolysis. The one ormore insulators 476 prevent short circuit between the negatively chargedanodes 474 and positively chargedcathodes 472 and may serve as flexible, tolerance-compensating gaskets which delineate the cross-sectional boundary of eachchannel 462 and build/concentrate the forcedflow electrolyte stream 53 b within eachchannel 462. - As shown in
FIG. 18 , eachanode 474 may communicate with one ormore anode terminals 442.Anode terminals 442 may comprise, for example and without limitation, afastener 442 a such as a pin or screw, a clampingmember 442 b such as a nut, flange, or head, aterminal lead 442 c connected to a ground or power source, a conductive washer 442 d or other clamping member, aninsulative bushing 442 e to prevent electrical currents from passing to surrounding portions of thecell 42, a thread orequivalent securing feature 442 f provided on saidfastener 442 a, aconductive support 442 h comprising a complimentary thread or equivalent securing feature 442 g for communicating with said thread orequivalent securing feature 442 f, and a receivingportion 442 i provided within theconductive support 442 h for engaging and supporting one ormore anodes 474. In the particular embodiment shown,anodes 474 are generally tubular cylindrical sleeves and therefore, receivingportions 442 i may be provided as small straight or generally arcuate slits. However, other equivalent interfaces are envisaged, particularly for non-cylindrical ornon-tubular anodes 474 andcathodes 472. For example, instead of slits, receivingportion 442 i may comprise a plurality of conductive clamps, spring clips, or pegs extending from thesupport 442 h which straddle and secure ananode 474 thereto. - In some embodiments, the
continuous electrowinning system 40′ may be provided with acylindrical cell body 406, a flat circular upperfirst end 440, and a generally frustoconical lowersecond end 480. The frustoconical shape of the lowersecond end 480 generally aids in channeling collected heavy cathode sludge concentrate 53 f to thesecond outlet 430 for removal. Thefirst end 440 may be secured to thecell body 406 via anannular flange 445 which may be electrically neutral or positively charged with the rest ofcathodic cell body 406. Thefirst end 440 may comprise a series of sandwiched panels, such as one or more ground or electrically-neutral panels 447, one or moreanodic panels 444, and one or moreinsulative panels 446. In some embodiments the one or moreinsulative panels 446 may comprise a gasket, such as a polytetrafluoroethylene (PTFE) insulating gasket. One ormore fasteners 441 or adhesives may be provided to secure thefirst end 440 to thebody 406 and/or to secure sandwichedpanels fasteners 441 may be provided around a perimeter of thefirst end 440 to secure thefirst end 440 to theflange 445. Thefasteners 441 may be insulated, for example, with a sheath, coating, bushing, or washer of non-conductive material such as high molecular weight polyethylene (HMWPE), polyvinylidene fluoride (PVDF), polypropylene, or polyvinylchloride (PVC). Moreover, thefasteners 441 may serve the dual purpose of securing thefirst end 440 to thebody 406 and also securing sandwichedpanels - In use, an influent stream of
electrolyte solution 53 at a higher-than-ambient pressure and temperature continuously enters thecell 42 viainlet 410. Theelectrolyte solution 53 may contain metal ions of copper, gold, silver, platinum, lead, zinc, cobalt, manganese, aluminum, or uranium, without limitation. Thecontinuous electrowinning system 40′ is preferably maintained at a higher-than-ambient temperature (e.g., around 88 degrees Celsius) and/or pressure. The influent stream ofelectrolyte solution 53 may come from an upstream electrolyte holding tank (not shown), acontinuous elution system 20′, or a combination thereof. In some embodiments, theinlet 410 may be formed from a portion of a pipe or tubing having one or more sidewalls 412 and may further comprise aninlet mount 414 having a flange, seal, valve, pipe fitting, or equivalent connector for integration with thecontinuous elution system 20′.Inlet 410 comprises one or more openings 413 (e.g., through said one or more sidewalls 412), which are configured to feed said one ormore channels 462 of theresidence chamber 460 withincoming electrolyte solution 53. Though not shown, a plurality ofopenings 413 may be provided perchannel 462. In the eventmultiple channels 462 and asingle inlet 410 is employed as shown, the influent stream ofelectrolyte solution 53 may be split into a plurality of dispersedinfluent streams 53 a, each enteringdifferent channels 462. Alternatively, while not shown, aseparate inlet 410 may be provided for eachchannel 462. Theopenings 413 may be configured to provide uniform or non-uniform flow rates across eachchannel 462 or provide similar electrolyte residence times for eachchannel 462. As clearly shown inFIG. 17 , one or more insulators 417 (e.g., an insulation pad) may be placed between one or more sidewalls 412 of theinlet 410 and thefirst end 440 of thecell body 460. The one ormore insulators 417 may encircle the one ormore openings 413 to ensure thatincoming electrolyte solution 53 from dispersedinfluent streams 53 a does not form, plate, or sludge within theopenings 413, particularlyadjacent cathodes 472. - In some embodiments,
channels 462 may be configured to allow the dispersedinfluent streams 53 a ofelectrolyte solution 53 to flow forcedly through thechannels 462 in a forcedflow electrolyte stream 53 b which follows a uniform helical or spiral path as shown. However, while not shown, thechannels 462 may also be configured to direct the dispersedinfluent streams 53 a along straight paths, serpentine paths, compound curve paths, or complex 3D-spline curve paths so long as they can support a forcedflow electrolyte stream 53 b therein and provide a sufficient residence time of electrolyte between ananode 474 andcathode 472. -
Channels 462 may shrink or grow in circumference or change in overall or cross-sectional shape and/or size as they extend within theresidence chamber 460; however, it is preferred thatchannels 462 remain uniform in cross-section, direction, and/or anode-cathode spacing throughout their entire length. While not shown, sincechannels 462 located at greater radial distances from the center of thecell 42 are longer and will generally have higher residence times thaninner channels 462, the number of turns of inner channels 462 (e.g., channels adjacentinner anode 477 and first chamber 405) may be adjusted to be greater than the number of turns for outer channels 462 (e.g., channels more proximate theouter anode 479 and third chamber 408). In other words, while not shown, inner portions ofresidence chamber 460 may be greater in height than outer portions ofresidence chamber 460, in order to lengthen the effective length of inner channels 462 (adjacent the first chamber 405). Portions ofbaffle 450 adjacent theresidence chamber 460 andthird chamber 408 are generally open so as to allowchannels 462 to continuously deliver spentelectrolyte streams 53 d to thethird chamber 408 and collected cathode sludge concentrate 53 f formed in thechannels 462 to thesecond chamber 407. - As shown in
FIG. 16 ,baffle 450 may comprise ananodic layer 452, a middle electrically-neutral insulator 454 to support said one ormore anodes 474 andcathodes 472, and asupport structure 456 for supporting theinsulator 454 andanodic layer 452. Theinsulator 454 may be made of a chemically-robust material such as ultra-high molecular weight polyethylene (UHMWPE) and may be cruciform in shape as shown. A plurality of receivingportions 458 such as notches may be provided to theinsulator 454 to hold, space, insulate, and support the one ormore anodes 474 andcathodes 472; however, other holding means such as pegs, spring clips, or clamps may be provided. Theinsulator 454 may be connected to thesupport structure 456 with one or more fasteners, adhesives, or other connecting means, and thesupport structure 456 may be connected to thebody 406 by conventional means such as bolting, forming, adhering, welding, or supporting on a flange or shelf. Theanodic layer 452 may serve to close off thefirst chamber 405 and preventelectrolyte 53 in the forcedflow electrolyte stream 53 b from entering saidfirst chamber 405. In some embodiments, thesupport structure 456 may be a lattice structure such as a mesh screen or supporting member such as a crossbar which spans a width of thecell body 406.Support structure 456 is generally configured not to inhibit electrolyte flowing from thechannels 462 to thethird chamber 408, or inhibit the passage of cathode sludge concentrate 53 f to thesecond chamber 407. - As
electrolyte solution 53 forcibly flows through the one ormore channels 462 in theresidence chamber 460, a large electric potential is placed between the one ormore anodes 474 and one ormore cathodes 472 in order to effectively “plate-out” sludge concentrate onto the one ormore cathodes 472. However, by varying operating parameters such as residence time, electric current, electrolyte flow rate, temperature, pressure, electrolyte concentration/composition, and/or smoothness/material/coating of each cathode(s) 472, thechannels 462 may be configured such that cathodic sludge concentrate initially forms on or adjacent to the one ormore cathodes 472, but will not actually bond or “plate” to thecathodes 472 and will instead flush down thechannels 462 and/or become suspended in the forced flow electrolyte streams 53 b. Any sludge concentrate that may settle to bottom of achannel 462 may also be washed down and eventually swept out of thechannels 462 and intosecond chamber 407 by the forced flow electrolyte streams 53 b. Sludge concentrate may be flushed out of the one ormore channels 462 by virtue of: gravitational forces acting on inclined surfaces, high flow rates of forced flow electrolyte streams 53 b passing through the one ormore channels 462, increased turbulence within eachchannel 462, and/or by virtue of small cross-sectional areas provided to eachchannel 462. - After the forced flow electrolyte streams 53 b pass through the one or
more channels 462, theoutflow 53 c of theresidence chamber 460 will generally comprise a liquid carrier component ofbarren solution 54 which is substantially-free of dissolved precious metal, and a solid precipitate component comprising cathodic sludge concentrate which has been discharged from thechannels 462 by the forcedflow electrolyte stream 53 b. The heavier solids may follow a sludge precipitate stream 53 e before settling in a mass of collected cathode sludge concentrate 53 f within thesecond chamber 407 adjacent thesecond end 480.Barren solution 54 travels via spentelectrolyte stream 53 d into thethird chamber 408 and continuously leaves thecell 42 throughoutlet 420. In embodiments where thecell body 406 is cathodic, some residual plating or cathodic sludge concentrate formation may occur within the third chamber 408 (for example, on or around inner portions of cathodic sidewall(s) 482). However, any cathode sludge concentrate 53 f formed within thethird chamber 408 will typically settle and eventually end up insecond chamber 407 with the rest of the collected cathode sludge concentrate 53 f. - The
first outlet 420 may be formed from a portion of a pipe or tubing having one or more sidewalls 422 and may further comprise afirst outlet mount 424 having a flange, seal, valve, pipe fitting, or equivalent connector for integration with acontinuous elution system 20′. When in use, an effluent stream ofbarren solution 54 continuously leaves thecell body 406 through saidfirst outlet 420 at which point it may enter a barren solution holding tank (not shown), be discarded, return to acontinuous elution system 20′, or undergo further processing. - Captured cathode sludge concentrate 53 f may be removed from the
cell 42 intermittently or continuously viasecond outlet 430. The underflow, orsludge removal stream 53 g of cathode sludge concentrate 53 f may proceed to a holding tank, be pumped away for further refining, or may be dumped into a container and transported to a smelter. In some embodiments, thesecond outlet 430 may be formed from a portion of a pipe or tube having one or more sidewalls 432 and may further comprise asecond outlet mount 434 having a flange, seal, valve, pipe fitting, nozzle, tap, or equivalent connector for integration with a holding tank or smelting apparatus. - The cross-section of
residence chamber 460 may vary, so long as one ormore channels 462 therein are formed between at least oneanode 474 and at least onecathode 472 which are separated from each other by one ormore insulators 476. Channels may extend linearly (resembling an elongated pipe), helically, in a cascade of connected, horizontally-arranged, and vertically-displaced “figure-8s”, or in any continuous path in 3-D space which is configured to provide a “forced flow” of electrolyte solution. In order to assist with outgassing of air which could get caught in thechannels 462 and also prevent the backup of precipitated sludge concentrate within the channels, it is preferred that the continuous path the channels follow in 3-D space be free of sharp bends, abrupt turns, overhangs, high spots, and/or tightly wound corners which may be prone to air capture and clogging. In some embodiments, aresidence chamber 460 may comprise one ormore channels 462 therein which simply extend as long straight pipe sections tilted at an angle with respect to horizontal. -
FIG. 19 schematically illustrates acontinuous electrowinning process 40 according to some embodiments. Theprocess 40 comprises providing 1082 anelectrolyte solution 53 having an elevated temperature or pressure with respect to ambient conditions. Theelectrolyte solution 53 may be produced from acontinuous elution process 20 and may comprise water, cyanide, caustic, and a dissolved metal (e.g., gold, copper, silver, platinum, aluminum, lead, zinc, cobalt, manganese, or uranium) therein. Theelectrolyte solution 53 is continuously fed 1084 (e.g., at a predetermined flow rate) into a continuous electrolyticmetal recovery cell 42 which is preferably maintained 1086 at a higher-than-ambient temperature and/or pressure. In some embodiments, thecell 42 may comprise a series of nestedanode sleeves 474 andcathode sleeves 472, wherein adjacent sleeves have a different electrical potential or charge. In a preferred embodiment, the sleeves are spaced concentrically and radially evenly with respect to each other so that any two neighboring sleeves hold anopposite charge 1088. One ormore insulators 476 may be placed between theanodes 474 andcathodes 472 to define a plurality of channels 462 (e.g., helical channels) and simultaneously prevent arcing between the anodes and cathodes. Theprocess 40 further comprises subjecting 1090 theelectrolyte solution 53 to a longer residence time within a continuous electrolyticmetal recovery cell 42. This may be achieved by providing one or moreelongated channels 462 between theanode 474 andcathode 472 sleeves, which extend in smooth, continuous, and uninterrupted helical paths. It should be known that residence time may also be increased by alternatively employing long tubular straight channels.Electrolyte solution 53 maintained within thechannels 462 is forced through thechannels 462 and walls thereof by small pressure differentials between the inlet 110 and the first 120 outlet and/or small pressure differentials between the inlet 110 and the second 130 outlet. As theelectrolyte solution 53 moves through thechannels 462, cathodic sludge concentrate precipitates out of theelectrolyte solution 53 until the solution becomes weaker in concentration and eventually substantially-free ofprecious material 1092. Precipitating concentrate from the sludge precipitate stream 53 e is continuously collected 1094 withinsecond chamber 407, and collected cathode sludge concentrate 53 f may be extracted 1098 continuously or intermittently or a combination thereof. A stream of barren solution 54 (which is substantially devoid of precious metal) is continuously extracted 1096 from thecell 42 viaoutlet 420, and may be fed to acontinuous elution vessel 24 within acontinuous elution process 20. -
FIG. 20 shows acarbon regeneration process 30 according to some embodiments. Asolids fraction 55 of concentrated spentslurry 51 d comprising spent de-watered carbon is sifted with ascreen 32 to separate out spentcarbon fines 55 b. The spentcarbon fines 55 b are placed in a carbonfines holding tank 34. The remaining course spentcarbon 55 a is sent to a regeneration kiln 35 (or other means for regeneration such as a chemical, steam, or biological process). Hot reactivatedcarbon 55 c is removed from theregeneration kiln 35 and quenched in a carbon quenchtank 36. A slurry of cooled regenerated carbon and fluid moves to adewatering screen 37 viapump 33. After passing throughdewatering screen 37, dewatered activated/reactivatedcarbon 56 is moved to a continuous carbon loading/adsorption process 70. The fluid underflow, which comprises cool reactivatedcarbon slurry 55 d, is moved to the carbonfines holding tank 34. -
FIG. 21 shows a continuousmetal recovery system 100′ according to some embodiments of the invention comprising a continuousacid wash system 10′, acontinuous elution system 20′, acontinuous electrowinning system 40′, and acarbon regeneration system 30′.FIGS. 22 and 23 serve to compare scale plant layouts and overall footprints.FIG. 22 shows thesystem 100′ for the continuous recovery of metals according toFIG. 21 andFIG. 23 comprises aconventional system 9000′ for the batch recovery of metals using “batch” process steps. As can be seen fromFIGS. 22 and 23 , thesystem 100′ according to the invention is smaller in size than theconventional system 9000′ depicted inFIG. 23 . In addition to smaller size,system 100′ is also more efficient and environmentally-friendly. -
FIG. 24 shows an alternative to thewashing tanks FIGS. 6-8 . In the embodiment shown, anacid wash tank 2000 is provided, which may replaceacid wash tank 200.Acid wash tank 2000 comprises awash chamber 2020 having afluidized bed panel 2021 spanning the length of thewash chamber 2020 with pore sizes smaller than the mean particle size of loaded/reloaded carbon, one or moreadjustable mounts chamber 2020 with respect to askid 2002, arecirculation inlet 2023 a provided below thefluidized bed panel 2021, and arecirculation outlet 2023 b provided above thefluidized bed panel 2021.Recirculation outlet 2023 b comprises one ormore overflow outlets 2027, each provided with at least one washable/replaceable recycle screen 2008, which maintains loaded/reloadedcarbon 57 within thechamber 2020 and filters exitingdilute acid solution 57 c.Recycle screens 2008 may be conveniently provided between bolted flange members of theoverflow outlets 2027 and may comprise built-in peripheral gaskets.FIGS. 25 and 26 show more detailed views of thechamber 2020 shown inFIG. 24 . -
Recirculation inlet 2023 a may comprise one or moreadjustable nozzles 2011 which serve to fluidize loaded/reloadedcarbon 57. Thenozzles 2011 may be individually or collectively angularly adjusted and “set” to a fixed angle, in order to: compensate for various inclinations of thechamber 2020, prevent buildup of loaded/reloadedcarbon 57, and counteract backflow within thechamber 2020 caused by eddy currents surrounding interior baffles 2018.Chamber 2020 may, as shown, be constructed in clamshell form, with a number offasteners 2004 connecting upper and lower clamshell portions together. One or more additional gaskets may be employed between the upper and lower clamshell portions to form a seal, or thefluidized bed panel 2021 itself may be provided with peripheral gasketing material properties to provide a seal between the upper and lower clamshell portions. - A
first filter 2001 is provided at aninlet 2022 to theacid wash tank 2000. Thefirst filter 2001 comprises ahousing 2003 which serves to collects influent loaded/reloadedcarbon slurry 57′, afirst screen 2026 which serves to separate loaded/reloadedcarbon 57 fromcarrier fluid 57 f present in theslurry 57′, afirst filter outlet 2006 which serves to transfer strained loaded/reloadedcarbon 57 from within theupper housing 2003 to thewash chamber 2020, arecirculation tank 2029 which collectscarrier fluid 57 f separated from the liquid fraction of theinfluent slurry 57′, and one ormore clamps 2005 which removably attach thehousing 2003 to therecirculation tank 2029 with thefirst screen 2026 extending therebetween, thereby allowing periodic cleaning and/or replacing of thefirst screen 2026.Recirculation tank 2029 may be configured to continuously redistributecarrier fluid 57 f to a holding tank (not shown) or may simply comprise a valve for batch removal of the collectedcarrier fluid 57 f. - A
second filter 2024, similar to thefirst filter 2001, is provided adjacent afirst channel 2082 extending from thefluidized bed panel 2021 to an outside portion of thewash chamber 2020.First channel 2082 is configured to provide egress of acid-rinsed loadedcarbon 57 a resting on/around/abovefluidized bed panel 2021 after it has undergone a predetermined residence time of acid washing within thechamber 2020. The acid-rinsed loadedcarbon 57 a is filtered by asecond screen 2036, and the strained solids fraction of the acid-rinsed loadedcarbon 57 a exits adischarge outlet 2028. The acid-rinsed loaded carbon exiting thedischarge outlet 2028 may be captured and contained by aholding tank 2060 and subsequently transported (via pump 2030) to a downstream process (e.g., aqueous rinse cycle). Alternatively, the acid-rinsed loaded carbon exiting thedischarge outlet 2028 may directly enter a downstream process (e.g., pour into another aqueous rinsetank 200′ without anintermediate holding tank 2060 and pump 2023).Holding tank 2060 advantageously serves as a buffer which maintains a level of process control and prevents too much carbon feed to downstream processes. - In use, replenished
dilute acid solution 57 c′ (obtained by filtering acid-rinsed loadedcarbon 57 a with second screen 2036) entersrecirculation tank 2039 and is pumped tochamber 2020 via a pump 2030. The replenisheddilute acid solution 57 c′ enters therecirculation inlet 2023 a and then passes upwards throughfluidized bed panel 2021 vianozzles 2011. The replenisheddilute acid solution 57 c′ suspends incoming loaded/reloadedcarbon 57, and moves the loaded/reloadedcarbon 57 through thechamber 2020 and around baffles 2011 for a predetermined residence time. The replenisheddilute acid solution 57 c′ passes throughrecycle screens 2008 and filtereddilute acid solution 57 c re-enters therecirculation tank 2039 viarecirculation outlet 2033 b. Residence time of the loaded/reloadedcarbon 57 may be increased or decreased by adjusting the inclination angle of thechamber 2020 and/or adjusting the angular orientation ofnozzles 2011. For a fixed, non-variable metal extraction process, the inclination angle ofchamber 2020 and angular positions of nozzles may be preset by the manufacturer and permanently fixed in the optimum configuration to yield the most efficient residence time for said process. - A water-based, loaded
carbon slurry 57 comprising approximately 30-300 oz/ton gold and approximately 30% wt/wt, activated coconut shell carbon is delivered to a continuousacid wash system 10′. First, inorganic components, namely calcium and magnesium carbonate, are removed from the loaded carbon by fluidizing a bed of loaded active carbon with a dilute aqueous acid solution comprising approximately 1-5 wt % hydrogen chloride (HCl) and/or nitric acid (HNO3) in anacid wash tank tank tank tank - The basic descaled loaded
carbon 50 is fed continuously to asplash vessel 22 within acontinuous elution system 20′ via a transfer medium of caustic strip solution comprising approximately 1 wt % caustic (NaOH) and 0.1 wt % cyanide (NaCN). Thesplash vessel 22 is generally held at an operating temperature between approximately 100 and 200 degrees Fahrenheit (° F.), and at a pressure of approximately atmospheric level. The loaded carbon is transferred from thesplash vessel 22 to thecontinuous elution vessel 24, where the gold is removed from the carbon (i.e., gold dissolution). Thecontinuous elution vessel 24 operates at roughly 300 degrees Fahrenheit (° F.), which temperature is achievable by elevating the strip solution pressure to roughly 70 psi (gauge). Thecontinuous elution vessel 24 continuously discharges into a lowerpressure flash vessel 25. A drop in pressure between thecontinuous elution vessel 24 andflash vessel 25 causes rapid flash vaporization of a portion of the effluent caustic strip solution. Steam generated is channeled to thesplash vessel 22, thereby simultaneously heating thesplash vessel 22 and cooling theflash vessel 25. Spent carbon, (e.g., comprising less than 1 oz/ton gold), is continuously moved out of thecontinuous elution system 20′ and into aregeneration process 30. - The approximately 300° F. pressurized caustic strip solution is filtered by one or more screens or
filters 324 to remove barren carbon particulate and formelectrolyte solution 53, which is then passed through a continuous electrolytic metal extraction (i.e., electrowinning)cell 42. Theelectrolyte solution 53 is forced (via the increased pressure provided by the continuous elution vessel 24) through at least onechannel 462 having a fixed helical path between acylindrical sleeve anode 474 and acylindrical sleeve cathode 472. A voltage between approximately 2 and 4 volts is passed between theanode 474 through theelectrolyte solution 53 and thecathode 472, thereby depositing cathode sludge concentrate 53 f on surfaces of thecathode 472. The velocity of theelectrolyte solution 53 creates a forcedflow electrolyte stream 53 b within thechannel 462 which continuously washes the collected cathode sludge concentrate 53 f which may form and collect on the cathode's surfaces to the conical bottom of thecell 42, where it may be removed at the operator's leisure or continuously via a control valve. - A contractor or other entity may provide a
system 100′ orprocess 100 for the continuous recover of metals in part or in whole as shown and described. For instance, the contractor may receive a bid request for a project related to designing a continuousmetal recovery system 100′ orprocess 100, or the contractor may offer to design such asystem 100′ or aprocess 100 for a client. The contractor may then provide, for example, any one or more of the devices or features thereof shown and/or described in the embodiments discussed above. The contractor may provide such devices by selling those devices or by offering to sell those devices. The contractor may provide various embodiments that are sized, shaped, and/or otherwise configured to meet the design criteria of a particular client or customer. The contractor may subcontract the fabrication, delivery, sale, or installation of a component of the devices or of other devices used to provide such devices. The contractor may also survey a site and design or designate one or more storage areas for stacking the material used to manufacture the devices. The contractor may also maintain, modify, or upgrade the provided devices. The contractor may provide such maintenance or modifications by subcontracting such services or by directly providing those services or components needed for said maintenance or modifications, and in some cases, the contractor may modify an existingmetal recovery process 9000 orsystem 9000′ with a “retrofit kit” to arrive at a modified process or system comprising one or more method steps, devices, or features of thesystems 100′ and processes 100 discussed herein. - Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. For example, particulates and carriers other than carbon (e.g., polymers or ion exchange resins) may be used with the disclosed systems and processes. Moreover, reagents other than water, cyanide, and caustic may be used to wash, descale, or strip the particulates. Furthermore, the disclosed systems and processes may be used to recover numerous types of materials including, but not limited to copper, gold, silver, platinum, uranium, lead, zinc, aluminum, chromium, cobalt, manganese, rare-earth and alkali metals, etc. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
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Reference numeral identifiers 10 Continuous acid wash process 10′ Continuous acid wash system 12 Acid wash tank 13 Pump 14 Aqueous rinse tank 16 Caustic rinse tank 20 Continuous elution process 20′ Continuous elution system 21 Steam return 22 Splash vessel 23 Pump 24 Continuous elution vessel 25 Flash vessel 26 Dewatering screen 27 Immersion heater 28a Influent manifold 28b Effluent manifold 29 Valve 30 Carbon regeneration process 30′ Carbon regeneration system 32 Screen 33 Pump 34 Carbon fines holding tank 35 Regeneration kiln 36 Carbon quench tank 37 Dewatering screen 40 Continuous electrowinning process 40′ Continuous electrowinning system 42 Continuous electrolytic metal extraction cell 50 Descaled loaded carbon (or caustic/basic slurry thereof) 51 Slurry of strip solution and descaled loaded carbon 51a Heated and/or pressurized slurry 51b Serpentine flow path of slurry 51c Spent slurry 51d Concentrated spent slurry 52 Liquid fraction of concentrated spent slurry 53 Electrolyte solution 53a Dispersed influent stream 53b Forced flow electrolyte stream 53c Residence chamber outflow 53d Spent electrolyte stream 53e Sludge precipitate stream 53f Cathode sludge concentrate 53g Sludge removal stream 54 Barren solution (i.e., spent electrolyte) 55 Solids fraction of concentrated spent slurry (e.g., de-water 55a Course spent carbon 55b Spent carbon fines 55c Hot reactivated carbon 55d Cool reactivated carbon slurry 56 Activated/reactivated carbon 57′ Loaded/reloaded carbon slurry 57 Loaded/reloaded carbon 57a Acid-rinsed loaded carbon 57b Rinsed loaded carbon 57c, 57c′ Dilute acid solution 57d, 57d′ Aqueous rinse solution 57e Caustic rinse solution 57f Carrier fluid 60 Holding tank 70 Continuous carbon loading/adsorption process 70′ Continuous carbon loading/adsorption system 100 Process for the continuous recovery of metals 100′ System for the continuous recovery of metals 200 Acid wash tank 200′ Aqueous rinse tank 200″ Caustic rinse tank 220 First chamber 221 First fluidized bed panel 222 First inlet 223a First recirculation inlet 223b First recirculation outlet 224 First weir 226 First screen 227 First overflow outlet 228 First discharge outlet 229 First recirculation tank 230 Second chamber 231 Second fluidized bed panel 232 Second inlet 233a Second recirculation inlet 233b Second recirculation outlet 234 Second weir 236 Second screen 237 Second overflow outlet 238 Second discharge outlet 239 Second recirculation tank 240 Third chamber 241 Third fluidized bed panel 242 Third inlet 243a Third recirculation inlet 243b Third recirculation outlet 244 Third weir 246 Third screen 247 Third overflow outlet 248 Third discharge outlet 249 Third recirculation tank 251 Acid overflow 253 Drained acid return 254 Rinse water overflow 256 Drained rinse water return 257 Caustic rinse overflow 260 Bottom wall 266 Inner tubular wall 268 Outer tubular wall 282 First channel 284 Second channel 286 Third channel 301 Inlet seal 302 Inlet mount 304 Inlet 306 First end 308 Second end 310 One or more sidewalls 312 Effluent port mount 314 Mounting member 316 Effluent port 318 One or more baffles 320 Fluidized bed panel 322 Influent port mount 324 Filter (e.g., disk screen) 326 Influent port 328 Outlet 329 Outlet seal 330 Outlet mount 340 Residence chamber 350 Fluidizing chamber 402 Mount 404 Base 405 First chamber 406 Cell body 407 Second chamber 408 Third chamber 410 Inlet 412 One or more inlet sidewalls 413 One or more openings 414 Inlet mount 417 One or more insulators 420 First outlet 422 One or more first outlet sidewalls 424 First outlet mount 430 Second outlet 432 One or more second outlet sidewalls 434 Second outlet mount 440 First end 441 Fastener 442 Anode terminal 442a Fastener 442b Clamp 442c Terminal lead 442d Conductive washer 442e Insulative bushing 442f Thread or equivalent securing feature 442g Complimentary thread or securing feature 442h Conductive support 442i Receiving portion 444 Anodic panel 445 Cathodic flange 446 Insulative panel 447 Anodic panel 450 Baffle 452 Anodic panel 454 Anode/Cathode insulator 456 Anode/Cathode insulator support 458 One or more receiving portions 460 Residence chamber 462 One or more channels 472 Cathode 473 One or more protuberances 474 Anode 476 One or more insulators 477 Inner anode 479 Outer anode 480 Second end 482 One or more sidewalls 1000 Process for the continuous recovery of metals 1002-1046 Continuous acid wash steps 1048-1080 Continuous elution steps 1082-1100 Continuous electrowinning steps 2000 Acid wash tank 2001 First filter 2002 Skid 2003 Housing 2004 Fastener 2005 Clamp 2006 First filter outlet 2007 First adjustable mount 2008 Recycle screen 2009 Second adjustable mount 2011 Nozzle 2018 Baffle 2020 Chamber 2021 Fluidized bed panel 2022 Inlet 2023 Pump 2023a Recirculation inlet 2023b Recirculation outlet 2024 Second filter 2026 First screen 2027 Overflow outlet 2028 Discharge outlet 2029 Recirculation tank 2033b Recirculation outlet 2036 Second screen 2039 Recirculation tank 2060 Holding tank 2082 First channel 9000 Conventional batch metal recovery process 9000′ Conventional batch metal recovery system 9100 Conventional batch acid wash process 9100′ Conventional batch acid wash system 9120 Acid wash vessel 9132 Pump 9134 Carbon transfer pump 9136 Pump 9140 Dilute acid tank 9150 Sump pump 9160 Neutralizing tank 9200 Conventional batch (Zadra strip) elution process 9200′ Conventional batch (Zadra strip) elution system 9220 Barren solution tank 9232 Carbon transfer pump 9234 Barren solution backup pump 9236 Barren solution pump 9237 Barren solution 9239 Hot barren solution 9240 Strip vessel 9250 Heating skid or equivalent heat exchanger 9300 Carbon regeneration process 9400 Conventional batch electowinning process 9400′ Conventional batch electowinning system 9420 Batch electrolytic metal recovery cell (e.g., removable plate cathodes) 9421 Hot electrolyte solution 9430 Pump 9440 Electrowinning pump box 9500 Descaled loaded carbon 9530 Electrolyte solution 9540 Barren solution 9550 Spent carbon 9560 Activated/reactivated carbon 9570 Loaded or reloaded carbon 9700 Conventional batch carbon loading process
Claims (17)
1. A system [100′] for the continuous recovery of metals comprising at least one of the following:
a continuous acid wash system [10′] configured for receiving a continuous, uninterrupted inflow of loaded carbonaceous particulate [57] and delivering a continuous, uninterrupted outflow of descaled loaded carbonaceous particulate [50];
a continuous elution system [20′] configured for receiving a continuous, uninterrupted inflow of a strip solution [51] containing a descaled loaded carbonaceous particulate [50] and delivering a continuous, uninterrupted outflow of electrolyte solution [53]; and,
a continuous electrowinning system [40′] configured for receiving a continuous, uninterrupted inflow of electrolyte solution [53], delivering a continuous uninterrupted outflow of a barren solution [54], and continuously and uninterruptedly forming a cathode sludge concentrate [53 f];
wherein each of the continuous acid wash system [10′], the continuous elution system [20′], and the continuous electrowinning system [40′] are configured to operate simultaneously without interruptions common with conventional batch metal recovery processes.
2. The system [100′] according to claim 1 , further comprising a carbon regeneration system [30′] operatively connected to said continuous elution system [40′].
3. The system [100′] according to claim 1 , further comprising a continuous carbon loading/activation system [70′] operatively connected to said continuous acid wash system [10′].
4. The system [100′] according to claim 1 , further comprising a holding tank [60] operatively connected between said continuous acid wash system [10′] and said continuous elution system [20′].
5. The system [100′] according to claim 1 , comprising all three of said continuous acid wash system [10′], said continuous elution system [20′], and said continuous electrowinning system [40′].
6. The system [100′] according to claim 1 , further comprising one or more pumps [13, 23, 33].
7. The system [100′] according to claim 1 , wherein said continuous elution system [20′] is operatively connected to the continuous electrowinning system [40′].
8. The system [100′] according to claim 7 , wherein continuous elution system [20′] further comprises one or more screens or filters [324] configured to prevent carbonaceous particulate from passing to the continuous electrowinning system [40′].
9. The system [100′] according to claim 1 , wherein the continuous acid wash system [10′] further comprises a chamber [220] adapted for retaining a fluidization medium; an inlet [222] adapted for receiving a feed containing loaded carbonaceous particulate [57]; a fluidized bed distribution panel [220] or other means adapted for fluidizing the loaded carbonaceous particulate [220] in the presence of said fluidization medium; an outlet [228] adapted to pass loaded carbonaceous particulate and fluidization medium from the chamber; and a screen [226] adapted to filter loaded carbonaceous particulate from a fluidization medium;
wherein the continuous elution system [20′] comprises a splash vessel [22], a continuous elution vessel [24], and a flash vessel [25], wherein the splash vessel [22] is operatively connected to the continuous elution vessel [24] in series, the continuous elution vessel [24] is operatively connected to the flash vessel [25] in series, and the splash vessel [22] is operatively connected to the flash vessel [25] in parallel; and,
wherein the continuous electrowinning system [40′] comprises a continuous electrolytic metal recovery cell [42] having a cell body [406] configured to maintain electrolyte solution [53] at a high pressure and/or temperature; at least one anode [474]; at least one cathode [472]; an inlet [410] configured for receiving a continuous, uninterrupted influent stream of electrolyte solution [53]; a first outlet [420] configured for discharging a continuous, uninterrupted effluent stream of barren solution [54]; a second outlet [430] configured for removing cathode sludge concentrate [53 f]; and a residence chamber [460] configured to continuously transfer electrolyte solution [53] from said inlet [410] to said first outlet [420] and increase residence time of said electrolyte solution between said at least one anode [474] and said at least one cathode [472], the residence chamber [460] comprising one or more channels [462] which are configured to provide a forced flow of electrolyte solution [53] therein which is strong enough to continuously dislodge and/or transport cathode sludge concentrate along said one or more channels [462] and eventually out of said residence chamber [460].
10. The system [100′] according to claim 1 , wherein said continuous acid wash system [10′] further comprises at least one of a dilute acid solution [57 c], an aqueous rinse solution [57 d], and a caustic rinse solution [57 e]; wherein the continuous elution system [20′] further comprises a solution containing at least one of a carbonaceous particulate loaded with a precious metal, an electrolyte solution, spent carbonaceous particulate, a caustic, an aqueous component, and cyanide; and wherein the continuous electrowinning system [40′] further comprises an electrolyte solution.
11. The system [100′] according to claim 1 , wherein the continuous acid wash system [10′], the continuous elution system [20′], and the continuous electrowinning system [40′] are each configured to increase a pressure and/or temperature of a solution or slurry contained therein.
12. The system [100′] according to claim 1 , wherein a carbon regeneration system [30′] is operatively connected to said continuous elution system [20′], a continuous carbon loading/activation system [70′] is operatively connected to said continuous acid wash system [10′], and the carbon regeneration system [30′] is operatively connected to said carbon loading/activation system [70′].
13. The system [100′] according to claim 1 , wherein said continuous acid wash system [10′] is operatively connected to the continuous elution system [20′].
14. A process [100] for the continuous recovery of a metal comprising:
continuously feeding [1004] a continuous wash system [10′] with particulate [57] loaded with a metal;
continuously washing [1006, 1020, 1034] said loaded particulate [57] within the continuous wash system [10′] to descale the loaded particulate;
continuously removing [1046] descaled loaded particulate [50] from said continuous wash system;
continuously loading [1050] a continuous elution system [20′] with said descaled loaded particulate [50];
continuously removing [1064] electrolyte solution [53] from said continuous elution system [20′];
continuously feeding [1066, 1082, 1084] a continuous electrowinning system [40′] with said electrolyte solution [53];
continuously removing [1070, 1096] barren solution [54] from said continuous electrowinning system [40′]; and,
continuously delivering [1072] said spent electrolyte solution to said continuous elution system [20′];
wherein each of the continuous wash system [10′], the continuous elution system [20′], and the continuous electrowinning system [40′] are operably connected and configured to allow the above steps to be performed simultaneously.
15. The process [100] according to claim 14 , further comprising forming said loaded particulate by continuously adsorbing metal onto said particulate in a continuous loading/adsorption system [70′] identical to said continuous wash system [10′].
16. The process [100] according to claim 15 , wherein said particulate is one of a carbonaceous particulate, a polymeric adsorbent, or an ion-exchange resin.
17. The process [100] according to claim 14 , further comprising continuously removing cathode sludge concentrate [53 f] from the continuous electrowinning system [40′].
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2012
- 2012-04-02 MX MX2013011323A patent/MX2013011323A/en not_active Application Discontinuation
- 2012-04-02 WO PCT/US2012/031845 patent/WO2012135826A1/en active Application Filing
- 2012-04-02 AU AU2012236120A patent/AU2012236120A1/en not_active Abandoned
- 2012-04-02 US US14/009,130 patent/US20140144788A1/en not_active Abandoned
- 2012-04-02 CA CA2831936A patent/CA2831936A1/en not_active Abandoned
- 2012-04-02 CN CN201280026375.4A patent/CN103582710A/en active Pending
-
2013
- 2013-09-30 CL CL2013002814A patent/CL2013002814A1/en unknown
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US5071477A (en) * | 1990-05-03 | 1991-12-10 | American Barrick Resources Corporation of Toronto | Process for recovery of gold from refractory ores |
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Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10435307B2 (en) | 2010-08-24 | 2019-10-08 | Private Equity Oak Lp | Evaporator for SAGD process |
US20120318682A1 (en) * | 2011-06-16 | 2012-12-20 | Korea Institute Of Geoscience And Mineral Resources (Kigam) | Electrowinning apparatus and method for recovering useful metals from aqueous solutions |
US8986519B2 (en) * | 2011-06-16 | 2015-03-24 | Korea Institute Of Geoscience And Mineral Resources (Kigam) | Electrowinning apparatus and method for recovering useful metals from aqueous solutions |
US10239766B2 (en) * | 2014-01-21 | 2019-03-26 | Private Equity Oak Lp | Evaporator sump and process for separating contaminants resulting in high quality steam |
US10047412B2 (en) * | 2015-01-15 | 2018-08-14 | Mintek | Gold recovery from carbon |
US10301180B2 (en) * | 2015-03-06 | 2019-05-28 | Jx Nippon Mining & Metals Corporation | Activated carbon regeneration method and gold recovery method |
US20210136879A1 (en) * | 2017-07-05 | 2021-05-06 | Daokorea Co.,Ltd. | Heating mat |
CN112375916A (en) * | 2020-11-04 | 2021-02-19 | 昆明理工精诚技术开发有限公司 | Copper-cobalt hydrometallurgy filtering and washing system and operation mode thereof |
Also Published As
Publication number | Publication date |
---|---|
MX2013011323A (en) | 2013-10-17 |
CL2013002814A1 (en) | 2014-06-27 |
CA2831936A1 (en) | 2012-10-04 |
AU2012236120A1 (en) | 2013-10-10 |
WO2012135826A1 (en) | 2012-10-04 |
CN103582710A (en) | 2014-02-12 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |