The development of a continuous reactor for the acid hydrolysis of cellulose and its application to refuse disposal

Refuse disposal in metropolitan areas is becoming increasingly difficult and expensive as ever-greater volumes of waste need to be transported to increasingly remote landfill sites. Acid hydrolysis offers an attractive alternative means of disposal, by aiming to convert the cellulose in the waste to glucose, for fermentation to ethanol. Recent research into the hydrolysis of cellulose at elevated temperatures and short reaction times has shown that high yields of glucose may be obtained: but experimental work with refuse has been lacking. This work describes the development of a continuous reactor for carrying out the hydrolysis of refuse under the conditions required for the determination of reaction rate data. An existing rig was modified through a series of preliminary experiments: after this, detailed testwork was carried out with filter paper, newsprint and air-classified lights of municipal refuse as cellulosic substrates, as well as pure glucose, to investigate the decomposition reaction. High yields of glucose were obtained from experiments with newsprint and refuse, and the kinetic parameters derived were compared with those of previous researchers. The data obtained from the hydrolysis of the refuse sample was used-to draw up a preliminary design of a 500 tonne/day plant to treat the air- classified light fraction of municipal refuse. The initial capital investment was estimated to be f8.1 million, and under present market conditions, it was shown to be advantageous to convert the cellulosic fraction of refuse into ethanol rather than RDF pellets. A rough estimate of a complete process to produce ethanol from untreated refuse indicated that considerable savings in overall disposal costs could be made, compared with disposing of the waste in the usual way, by landfilling after shredding or pulverisation

Heap leaching technology – current state, innovations and future directions: A review

Copyright © 2015 Taylor & Francis. This is an Accepted Manuscript of an article published by Taylor & Francis in Mineral Processing and Extractive Metallurgy Review on 20 November 2015, available online: http://www.tandfonline.com/10.1080/08827508.2015.1115990Heap leaching is a well-established extractive metallurgical technology enabling the economical processing of various kinds of low-grade ores, which could not otherwise be exploited. However, despite much progress since it was first applied in recent times, the process remains limited by low recoveries and long extraction times. It is becoming increasingly clear that the choice of heap leaching as a suitable technology to process a particular mineral resource, which is both environmentally sound and economically viable, very much depends on having a comprehensive understanding of the underlying fundamental mechanisms of the processes and how they interact with the particular mineralogy of the ore body under consideration. This paper provides an introduction to the theoretical background of various heap leach processes, offers a scientific and patent literature overview on technology developments in commercial heap leaching operations around the world, identifies factors that drive the selection of heap leaching as a processing technology, describes challenges to exploiting these innovations, and concludes with a discussion on the future of heap leaching.South Africa Research Chair Initiative (SARChI) - Chair in Mineral BeneficiationNational Research Foundation (NRF) of South Africa - Research Niche Area (RNA) gran

Investigation and modelling of the progression of zinc leaching from large sphalerite ore particles

X-ray Computed Tomography (CT) was used to follow the progression of Zn leaching in a number of individual sphalerite ore particles, which were subjected to a long-term simulated heap bioleaching environment. The ore was prepared by two different modes of comminution – HPGR at 90 bar and cone crusher – and individual particles were selected from three different size fractions. Investigation of the reacted fraction of Zn vs distance from the centre of each particle indicated that leaching from large particles leads to near complete conversion near the surface, but only partial conversion in the zones that are closer to the centre of particles. The cores of the cone-crushed particles show hardly any conversion at all, especially in the larger particle sizes. Mathematical analysis shows that leaching from the large particle does not follow the shrinking core model. It is shown that the progression can rather be described by a combined reaction-diffusion process progressing through the network of cracks and pores closer to the particle surface. Extent and depth of this network are a function of particle size and comminution method. A simplified rate model is proposed that describes the extent of leaching as a function of time in terms of a set of parameters that can all be related to just particle size and crushing mode

Investigation of particles with high crack density produced by HPGR and its effect on the redistribution of the particle size fraction in heaps

The application of comminution technology such as the High-pressure grinding rolls (HPGR), which is able to generate a high density of cracks in the ore particles, is favourable for leaching processes. Extraction of metallic values by the heap leach process, can take place on the particles with partial exposure of mineral grains, if it can provide sufficient surface front for chemical attack by leaching solution. The aim of this study was to assess the benefits of high crack density in the ore particles produced using the HPGR and how it could diminish due to inadequate percolation of the leaching agent. A zinc ore was comminuted using HPGR at three different pressure settings and with a cone crusher for the control experiment. Subsamples from the (+23/-25, +14/-16, +5.25/-6.75 mm) size fractions were characterized and packed into leach reactors. The reactors were stopped from time to time to investigate the progress of crack and micro-crack growth and its effect on metal extraction using the X-ray computed tomography (CT). The results are validated with those obtained using traditional techniques such as SEM and QEMSCAN. Investigation of the leach reactors residue indicated significant changes in the particle size distribution (PSD) of initial feed toward the fine size fraction. The residues from the reactors leaching the material prepared using the HPGR product contained more fine particles than the reactors, which were fed by cone crusher product. These differences were up to 10.3%

Assessment of reagent and regrinding in a flotation circuit

Laboratory flotation tests using a bottom driven cell are reproduced with a high level of confidence. These types of laboratory data are used to investigate the effect of reagent and regrinding of coarse particles in an industrial flotation circuit. The addition of collector (BX) has a significant effect on the flotation response of chalcopyrite in the scavenger bank. The reconstructed recovery-time curve (combine products) is greater than that of the rougher tailings (scavenger feed) prior to reagent addition. By adding collector (BX) in the scavenger feed, the ultimate recovery of chalcopyrite increases 20% which means an increase of 1.7% of chalcopyrite recovery in the scavenger feed. Meanwhile, the reagrinding of coarse particles shows a detrimental effect on the collectorless flotation of an initially hydrophobic chalcopyrite sample. Cyclone underflow, 80% recovery at pH 7.7, was decreased to 40% after regrinding at the same range of pH. The chalcopyrite flotation response immediately after regrinding is severely retarded. It is assumed that the centrifugal action of the cyclone is another important factor restoring the chalcopyrite hydrophobic flotation due to the oxygenation of the slurry. Therefore, additional preconditioning time after a regrinding stage should have a positive change in the recovery of chalcopyrite. The overall flotation response before and after the regrinding stage showed that the cyclone underflow response is slightly slower compared with the combine feed in the first four minutes of flotation. This behavior is related to changes on surface chemistry because of the regrinding of coarse particles

Large particle effects in chemical/biochemical heap leach processes - A review

The application of heap leach technology to recovery of economically important metals, notably copper, gold, silver, and uranium, is wide-spread in the mining industry. Unique to heap leaching is the relatively coarse particle size, typically 12–25 mm top size for crushed and agglomerated ores and larger for run-of-mine dump leaching operations. Leaching from such large particles is commonly assumed to follow shrinking core type behaviour, although little evidence for the validity of this assumption exists. This review investigates the current state of knowledge with respect to the understanding of the characteristics and mineralogy of large particles and how these influence leaching in a heap context and the tools to characterize these. This includes the study of ore and particle properties, visualization techniques for ore characterization, the connection between comminution and leaching behaviour, as well as particle models within heap leach modelling. We contend that the economics of heap leaching are strongly governed by the trade-off between the slow rate and limited extent of leaching from large particles and the cost of crushing finer. A sound understanding of the underlying large particle effects will therefore greatly inform future technology choices in the area of heap leaching

Large particle effects in chemical/biochemical heap leach processes – A review

The application of heap leach technology to recovery of economically important metals, notably copper, gold, silver, and uranium, is wide-spread in the mining industry. Unique to heap leaching is the relatively coarse particle size, typically 12–25 mm top size for crushed and agglomerated ores and larger for run-ofmine dump leaching operations. Leaching from such large particles is commonly assumed to follow shrinking core type behaviour, although little evidence for the validity of this assumption exists. This review investigates the current state of knowledge with respect to the understanding of the characteristics and mineralogy of large particles and how these influence leaching in a heap context and the tools to characterize these. This includes the study of ore and particle properties, visualization techniques for ore characterization, the connection between comminution and leaching behaviour, as well as particle models within heap leach modelling. We contend that the economics of heap leaching are strongly governed by the trade-off between the slow rate and limited extent of leaching from large particles and the cost of crushing finer. A sound understanding of the underlying large particle effects will therefore greatly inform future technology choices in the area of heap leaching