The Chemical Leaching Stage plays a pivotal role in the recovery of precious metals from materials such as spent catalytic converters. This process directly influences the overall efficiency and yield of metal recovery, making it a critical step in the refining cycle.
Key Features of the Chemical Leaching Process:
- Milled and Thermally Pre-Treated Material: The catalytic converter material is first milled and thermally pre-treated before being transferred to the leaching unit. This step ensures that the material is adequately prepared for effective leaching.
- Vacuum Transfer System: A vacuum transfer system is used to move the material to the leaching unit. This ensures clean and loss-free handling of the material, which is crucial for maintaining efficiency and preventing contamination.
- Chemical Solution: In the leaching unit, a specially formulated chemical solution dissolves all precious metals, including platinum, palladium, and rhodium. This solution is specifically designed to target and dissolve these valuable metals.
Design and Operation of the Chemical Leaching System:
- Agitation and Mass Transfer: The Chemical Leaching System consists of specially designed tanks that use mechanical agitation to maximize the contact between the black mass (processed catalytic converter material) and the leaching reagent. This ensures better mass transfer rates, homogeneous reagent distribution, and optimized metal dissolution.
- Advanced Control Systems: The system is equipped with advanced automation and control systems that maintain precise control over essential factors such as:
- Temperature
- Pressure
- Level
- Mixer SpeedThese controls are crucial for maintaining the efficiency, reliability, and safety of the process.
Heat Management in the Leaching Process:
- Temperature Regulation: Heat management is critical in the leaching process to maintain the ideal reaction conditions. The system incorporates:
- External jackets
- Internal coils
- Heat exchangersThese components regulate the temperature during the leaching process, enhancing heat transfer and ensuring consistent performance. By maintaining optimal temperatures, the system prevents overheating, which can compromise leaching efficiency and safety.
Advantages of the Chemical Leaching System:
- High Leaching Efficiency: The combination of mechanical agitation, precise control, and effective heat management ensures high leaching efficiency and excellent recovery rates of precious metals.
- Durable and Robust Design: Built for industrial-scale operations, the system’s durable structure ensures long-lasting performance and reliability, even under demanding operational conditions.
- Cost-Effective Operation: By optimizing the leaching process and integrating automation, the system reduces operational costs while maximizing recovery efficiency.
Eco-Friendly Approach:
- Proses Makina’s commitment to sustainability is evident in their design of the Chemical Leaching System. The system minimizes waste and ensures the recovery of valuable resources, aligning with eco-friendly practices that appeal to environmentally conscious customers.
Proses Makina’s Support:
- Maintenance and Training: Proses Makina offers comprehensive support, from equipment maintenance to operator training, ensuring that the leaching system runs smoothly and efficiently over its lifespan.
In summary, the Chemical Leaching System from Proses Makina offers a reliable, efficient, and eco-friendly solution for precious metal recovery, ensuring high yields and operational safety while minimizing environmental impact.
Technical Specifications
| Model | Processing Capacity | Reactor Volume | Operating Temperature | Operating pH | Agitator Power | Heating System | Installed Power | Approx. Dimensions (W × L × H) |
|---|---|---|---|---|---|---|---|---|
| CLS-100 | 100 kg/batch | 250 L | Ambient–95°C | 0–14 | 0.75 kW | Electric | 8 kW | 1,500 × 1,500 × 2,300 mm |
| CLS-250 | 250 kg/batch | 600 L | Ambient–95°C | 0–14 | 1.5 kW | Electric | 15 kW | 2,000 × 2,000 × 2,600 mm |
| CLS-500 | 500 kg/batch | 1,200 L | Ambient–95°C | 0–14 | 2.2 kW | Electric / Steam | 28 kW | 2,500 × 2,500 × 3,000 mm |
| CLS-1000 | 1,000 kg/batch | 2,500 L | Ambient–95°C | 0–14 | 4 kW | Steam / Thermal Oil | 45 kW | 3,200 × 3,500 × 3,500 mm |
| CLS-2000 | 2,000 kg/batch | 5,000 L | Ambient–95°C | 0–14 | 7.5 kW | Steam / Thermal Oil | 75 kW | 4,500 × 5,000 × 4,000 mm |
| CLS-5000 | 5,000 kg/batch | 12,000 L | Ambient–95°C | 0–14 | 15 kW | Steam / Thermal Oil | 145 kW | 6,000 × 7,500 × 5,000 mm |
Standard Technical Features
- High-efficiency chemical leaching reactor
- Heavy-duty top-entry agitator
- Automatic temperature control
- Automatic pH control
- Automatic reagent dosing
- PLC & Touchscreen HMI
- Acid and alkali resistant construction
- Variable-speed agitator (VFD)
- Heating jacket
- Cooling jacket (optional)
- Sampling ports
- Process vent connection
- Automatic level monitoring
- Load cell weighing (optional)
- SCADA compatibility
- Remote monitoring
Typical Leaching Reagents
- Hydrochloric Acid (HCl)
- Sulfuric Acid (H₂SO₄)
- Nitric Acid (HNO₃)
- Sodium Chlorate (NaClO₃)
- Hydrogen Peroxide (H₂O₂)
- Ferric Sulfate
- Sodium Cyanide (process dependent)
- Ammonia-based leachants
- Organic acids (application dependent)
Operating Conditions
| Parameter | Recommended Value |
|---|---|
| Operating Temperature | Ambient–95°C |
| Operating Pressure | Atmospheric |
| Operating pH | 0–14 |
| Slurry Density | Up to 45 wt.% |
| Mixing Speed | 20–250 rpm or more (depends on design) |
| Residence Time | 1–24 hours |
| Construction Material | PP, HDPE, Titanium, AISI 316L |
| Heating Control | Automatic PID |
Typical Feed Materials
- Black Mass
- Lithium-ion Battery Materials
- Catalytic Converters
- Electronic Scrap (WEEE)
- Copper Concentrates
- Nickel Concentrates
- Cobalt Concentrates
- Precious Metal Scrap
- Mining Concentrates
- Industrial Metal Residues
System Connections
- Feed inlet
- Reagent dosing inlet
- Water inlet
- Reactor overflow
- Product outlet
- Bottom discharge
- Vent outlet
- Condenser connection (optional)
- Temperature sensor
- pH sensor
- ORP sensor
- Level transmitter
- Electrical power supply