U.S. patent application number 09/746312 was filed with the patent office on 2001-05-03 for recovery of zinc from geothermal brines.
Invention is credited to Featherstone, John L..
Application Number | 20010000597 09/746312 |
Document ID | / |
Family ID | 23245177 |
Filed Date | 2001-05-03 |
United States Patent
Application |
20010000597 |
Kind Code |
A1 |
Featherstone, John L. |
May 3, 2001 |
Recovery of zinc from geothermal brines
Abstract
Improved methods are disclosed for the efficient and
cost-effective recovery of zinc metal from zinc-containing brines.
Zinc is first bound to an anionic ion exchange resin (IX) which has
been equilibrated with a solution containing a reducing agent,
washed, and eluted with an elution solution. A reducing agent can
be added to the brine prior to loading on the IX and can optionally
be added to the IX after the washing step. The eluted zinc is
extracted with a water-immiscible cationic organic solvent (SX),
which is scrubbed, then stripped with concentrated acid.
Substantially pure zinc is recovered by electrowinning the
zinc-loaded concentrated acid solution.
Inventors: |
Featherstone, John L.; (El
Centro, CA) |
Correspondence
Address: |
Laurie A. Axford
Morrison & Foerster LLP
Suite 500
3811 Valley Centre Drive
San Diego
CA
92130-2332
US
|
Family ID: |
23245177 |
Appl. No.: |
09/746312 |
Filed: |
December 20, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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09746312 |
Dec 20, 2000 |
|
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09320167 |
May 26, 1999 |
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Current U.S.
Class: |
205/605 |
Current CPC
Class: |
Y02P 10/234 20151101;
C22B 19/20 20130101; C25C 1/16 20130101; C22B 19/26 20130101; C22B
3/42 20130101; Y02P 10/20 20151101 |
Class at
Publication: |
205/605 |
International
Class: |
C25C 001/16 |
Claims
We claim:
1. A method for recovering substantially pure zinc metal from a
metal-containing brine, comprising: adding acid to said brine to a
pH of about 3.0 to about 3.5; loading a zinc-binding anionic ion
exchange chromatography resin (IX) with zinc by contacting said
brine with said IX, thereby forming a zinc-charged IX, wherein said
IX has been equilibrated with an equilibration solution comprising
a reducing agent prior to contacting said brine; washing said
zinc-charged IX with a hot acidic aqueous salt solution; eluting
said zinc-charge IX with an aqueous solution, thereby forming a
zinc-loaded eluate; extracting said zinc-loaded eluate by mixing
with a water-immiscible, cationic organic solvent (SX organic),
thereby forming a zinc-loaded SX organic; scrubbing said
zinc-loaded SX organic with an aqueous acidic solution; stripping
said zinc-loaded SX organic with an acid, thereby forming a
zinc-loaded electrolyte; and electrowinning zinc metal from said
zinc-loaded electrolyte.
2. The method of claim 1 wherein said hot acidic aqueous salt
solution is between about 170.degree. F. and 230.degree. F.
3. The method of claim 2 wherein said hot acidic aqueous salt
solution is about 190.degree. F.
4. The method of claim 1 wherein said IX is loaded in a column.
5. The method of claim 4 wherein pressure drop across the column
during said loading is maintained below 10 pounds per square
inch.
6. The method of claim 1 wherein said hot acidic aqueous salt
solution comprises 2.5% sodium chloride (w/v).
7. The method of claim 1 wherein a reducing agent is added to said
brine prior to loading said IX.
8. The method of claim 1 wherein said hot acidic aqueous salt
solution comprises a reducing agent.
9. The method of claim 7 wherein said reducing agent is sodium
formate.
10. The method of claim 8 wherein said reducing agent is sodium
formate.
11. The method of claim 9 wherein said sodium formate is present
from about 66 to about 500 parts per million (ppm).
12. The method of claim 10 wherein said sodium formate is present
from about 66 to about 500 parts per million (ppm).
13. The method of claim 1 wherein said Zn-loaded eluate is
concentrated before mixing with said SX.
14. The method of claim 1, further comprising washing said
Zn-loaded SX organic with water.
15. The method of claim 8, further comprising washing said
Zn-loaded SX organic with water.
16. The method of claim 1 wherein said acid is sulfuric acid.
17. The method of claim 16, wherein said sulfuric acid is about 150
to 190 grams/liter.
18. The method of claim 1, wherein said equilibration solution
comprises from about 66 to about 150 parts per million reducing
agent.
19. The method of claim 1, wherein said equilibration solution
comprises sodium formate.
20. The method of claim 19, wherein said equilibration solution
comprises sodium formate at a concentration of from about 66 to
about 150 parts per million.
Description
1. A improved process is provided for recovering substantially pure
zinc from geothermal brines containing metals. The improved process
comprises performing a first extraction step with an insoluble ion
exchange (IX) resin. Addition of the reducing agent significantly
reduces iron fouling and extends IX lifespan. The resin binds zinc
from the brine, and the resin is washed to remove residual brine.
The IX resin is eluted with a solution comprising a reducing agent.
The solution is then extracted with a cationic organic extractant
(SX). The SX organic phase is washed, then stripped with an aqueous
extractant, such as sulfuric acid. The zinc sulfate solution is
used as an electrolyte for electrowinning, to produce substantially
pure zinc metal.
TECHNICAL FIELD
2. The invention relates to the field of metal recovery from
solutions, particularly the recovery of zinc metal from geothermal
brines.
BACKGROUND ART
3. The term "brines," when used in its broad sense, includes brines
from a variety of sources, such as geothermal vents, oil drilling,
metal mining, and industrial waste and by-product streams. Such
brines frequently contain high concentrations of commercially
valuable metal ions.
4. Geothermal brines are of particular interest as they can be used
as a source of power for electricity production. In areas such as
California, subterranean pools of geothermal brines can be reached
by drilling. When piped to the surface, the highly pressurized and
heated brines "flash" to produce steam, which can be used to run
steam turbines and produce electricity. The "flashed" brine that
results from power production is frequently rich in commercially
valuable metals such zinc, silver, manganese, lithium and lead.
Recovery of dissolved metals from flashed steam used for power
generation is attractive as a sidestream or downstream process, and
has the potential to increase the overall profitability of
geothermal power operations.
5. Methods have been proposed for the recovery of metals from
flashed geothermal brines, such as that disclosed in U.S. Pat. No.
4,624,704. This patent discloses the use of a quaternary amine
(e.g., a methyl trialkyl ammonium chloride in which the alkyl group
is 8 to 10 carbon atoms) dissolved in a water immiscible organic
solvent for use in a single step liquid extraction. The loaded
solvent extractant is stripped by contacting it with an aqueous
sodium sulfate solution, resulting in an aqueous zinc
chloride/sodium sulfate phase and an immiscible zinc depleted
organic extractant phase.
6. Other methods rely on precipitation of metals from geothermal
brines. For example, Schultze et al. (Geothermal Resources Council,
Transactions, 6: 111-113, October, 1982) compare lime precipitation
with sulfide precipitation of metals from geothermal brines. This
disclosure teaches that precipitation methods can be quite
efficient (up to 95% of iron, manganese, lead and zinc can be
precipitate by the addition of lime). However, precipitation
methods also require that each particular metal be separated from
co-precipitated materials. Addition of lime also increases the pH
of the brine to levels which make reinjection of the spent brine
into the source geothermal formation difficult.
7. U.S. Pat. No. 5,229,003 discloses a method for zinc recovery
from geothermal brines that is of particular relevance. This patent
discloses the use of a two-step extract process which may utilize
either ion exchange (IX) or solvent (SX) extraction steps. While
the method disclosed in the '003 patent is minimally operable, it
suffers from several deficiencies that severely reduce its
industrial applicability. For example, this method is susceptible
to iron and calcium fouling on and in the IX resin, which reduces
the effectiveness and lifespan of the IX resin as well as the
profitability of the metal recovery process. The lifespan and
effectiveness of the IX resin are critical to the feasibility of a
metal recovery operation because IX resins are costly when used in
large amounts in metal recovery operations.
8. Accordingly, there is a need in the art for a method of
recovering zinc from zinc-containing brines at high efficiency and
low cost.
DISCLOSURE OF THE INVENTION
9. The invention is directed towards a process for the recovery of
substantially pure zinc (Zn) from brines which contain recoverable
amounts of Zn and other metals.
10. In one embodiment, brine is passed over an ion exchange (IX)
resin which binds zinc, wherein the resin has been pre-equilibrated
with a solution containing a reducing agent. The loaded resin is
washed with a hot aqueous acidic `salt wash`, then eluted with an
aqueous acidic solution containing a reducing agent. The metals
deleterious to downstream processes (e.g., iron, arsenic and lead)
are removed from the zinc-rich eluate by oxidation followed by
solids removal. The zinc is extracted from the eluate in a solvent
extraction (SX) process utilizing a water immiscible cationic
extractant (SX extractant). After removal of the aqueous
(Zn-depleted) phase, the Zn-loaded SX extractant is scrubbed with a
dilute acid solution, washed with reverse osmosis (RO) water and
then stripped with a sulfuric acid solution. The sulfuric acid/zinc
solution is separated from the stripped SX extractant and is used
for electrowinning of Zn.
11. In another embodiment, reducing agent is added to the brine
prior to loading onto the IX resin.
12. In a further embodiment, the loaded IX resin is backwashed
prior to elution.
13. In another embodiment, the SX organic phase is washed with 6
molar (M) HCl prior to remove accumulated iron from the organic.
This iron, if uncontrolled, seriously affects the performance of
the organic.
BRIEF DESCRIPTION OF THE DRAWINGS
14. FIG. 1 illustrates Stage 1A1 of the inventive method.
15. FIG. 2 illustrates Stage 1A of the inventive method.
16. FIG. 3 illustrates Stage 1B of the inventive method.
17. FIG. 4 illustrates Stage 1C of the inventive method.
18. FIG. 5 illustrates Stage 2A of the inventive method.
19. FIG. 6 illustrates Stage 2B of the inventive method.
20. FIG. 7 illustrates Stage 3A of the inventive method.
21. FIG. 8 illustrates Stage 3B1 of the inventive method.
22. FIG. 9 illustrates Stage 3B2 of the inventive method.
23. FIG. 10 illustrates Stage 3B2-1 of the inventive method.
24. FIG. 11 illustrates Stage 4A of the inventive method.
25. FIG. 12 illustrates Stage 4B of the inventive method.
26. FIG. 13 illustrates Stage 4C of the inventive method.
MODES FOR CARRYING OUT THE INVENTION
27. Materials and equipment for use in the instant invention must
be corrosion resistant, as Zn-containing brines can be highly
corrosive. Non-ferrous materials should be used for all wetted
surfaces. Materials and equipment experiencing high physical stress
should be constructed of high nickel, corrosion resistant alloys
such as Inconel 625, Hastelloy C276, Hastelloy C22 or other high
nickel, corrosion resistant metal alloys known in the art.
Materials and equipment experiencing low pressure static loads
(such as tank linings and the like) should be constructed of
corrosion resistant materials such as 2205 chrome duplex stainless
steel. Materials and equipment having a high leachable nickel
content, such as 304 and 316 austenistic stainless steels, should
be avoided where the material or equipment will be in prolonged
contact with a liquid (such as a tank lining) to avoid nickel
leaching into the liquid. Alternately, where possible, composite
materials, such as fiberglass-based composites, may be used.
28. Zinc-containing brines for use in the instant invention may be
from a variety of sources. Geothermal vents are an excellent source
of brines rich in zinc (Zn) and other metals. Other sources of
Zn-containing brines include brines formed as a by-product of oil
drilling, water outflow from copper mining operations, and
Zn-containing brines mined in locales such as Illinois and Missouri
in the United States. There is no preferred source of Zn-containing
brine, but certain brine characteristics are preferred. A
Zn-containing brine for use in the instant invention will
preferably have total dissolved salts (TDS) less than 32.2% (w/w),
more preferably less than 31.8% TDS. Preferred total suspended
solids (TSS) are less than 20 ppm. Acidified water of lower TDS and
TSS may be used to dilute the brine so that it falls within the
preferred specifications. However, any water used to dilute brine
must be de-aerated to an oxygen concentration of less than 300
parts per billion (ppb), preferably less than 20 to 50 ppb.
Deoxygenation of water may be accomplished by any method known in
the art, such as steam flushing, heating and de-aeration, and the
like.
29. Acid, preferably hydrochloric acid (HCl), is preferably added
to the brine prior to processing in accordance with the instant
method to prevent iron silicate precipitation. Scaling inhibitors
(compounds which prevent the precipitation of barium sulfate and
calcium fluoride) are also preferably added to the brine prior to
processing, as described in U.S. Pat. Nos. 5,268,108 and 5,288,411.
Examples of preferred scaling inhibitors include polyacrylate
dispersants and alkylaminophosphonates.
30. In the case where the brine is high in silica, the brine is
also preferably clarified prior to use in the instant method. A
preferred method of clarification involves collecting the brine in
a clarification tank under a steam blanket which provides three to
12 inches of water pressure. Silica particles are added to the
brine as "seed crystals." These promote the formation of silica
particles (approximately 5-15.mu. in size), thereby reducing the
quantity of silica in the brine. Silica particles are preferably
removed before the brine is subjected to the methods of the
invention. Silica particles may be removed by any convenient method
in the art, such as filtration, centrifugation,
settling/sedimentation, or a combination thereof.
31. A reducing agent may optionally be added to the brine. Examples
of reducing agents useful in accordance with the instant invention
include, but are not limited to, sodium dithionite, sodium
bisulfite, sodium sulfite, sodium thiosulfate, iron metal filings,
stannous chloride, aluminum metal powder, sodium formate,
formaldehyde, sodium formaldehyde bisulfite, sodium formaldehyde
sulfoxylate, carbon disulfide, sulfur, potassium iodide, potassium
cyanide, hydroquinone, phenol, t-butanol, ethylene glycol,
methanol, butyraldehyde, glyoxal and the like. The preferred
reducing agent is sodium formate. Generally, reducing agents may be
added at concentrations of up to about 750 ppm. If the reducing
agent is sodium formate, the concentration is preferably 10 to 750
ppm, more preferably 33 to 500 ppm, and most preferably 66 to 150
ppm. Addition of a reducing agent to the brine reduces scaling in
the IX resin and associated equipment due to ferric silicate
deposition.
32. The IX system employed in a preferred embodiment of the present
invention is a continuous batch operation. The brine feeds
continuously through a series of three-column "trains" of IX
columns. The number of trains varies depending on the design of the
brine and zinc flow. The brine flow rate, zinc concentration in the
brine, brine analysis and brine specific gravity are all factors
considered when setting up a system. Elution of each IX column is
completed on a batch basis and the frequency of elution is
dependent on the brine flow and zinc grade which dictate how
rapidly an IX column is loaded with zinc. During the loading stage
(1A1), the brine solution is delivered to the IX systems at
approximately 230.degree. F. and is introduced to the top of the
lead IX columns where the resin selectively retains the zinc.
33. The Zn-containing brine is passed over a strongly basic anionic
ion exchange resin (IX) that binds Zn. Preferred ion exchange
resins include the chloride form of quaternary amine
divinylbenzene/styrene copolymer (sold by Rohm & Haas as
Amberlite IRA-900 and Amberjet 4200Cl), the chloride form of
trimethylamine-functionalized chloromethylated copolymer of styrene
and divinylbenzene (sold by Dow Chemical as DOWEX 21K XLT), and the
chloride form of benzene, diethenyl polymer with ethenylbenzene,
chloromethylated, trimethylamino-quaternized (sold by Bayer as
Lewatit M510). IX resin may be loaded in batch or column formats,
although column format is preferred. For each loading cycle,
approximately 20 to 40 bed volumes of brine, preferably about 35
bed volumes, are passed over the IX resin.
34. It has been found that it is preferable that solutions coming
into direct contact with brine during the IX process contain a
reducing agent. Brine is frequently high in oxidizable metal ions,
particularly ferrous ions. Addition of a reducing agent to
solutions coming into contact with brine substantially reduces
oxidation of ferrous and other ions, inhibiting scale formation in
the IX resin and columns.
35. Prior to loading, the resin is preferably mixed or equilibrated
with acidic (pH 2) water containing a reducing agent. Reducing
agents useful in accordance with the instant invention include
sodium dithionite, sodium bisulfite, sodium sulfite, sodium
thiosulfate, stannous chloride, sodium formate, formaldehyde,
sodium formaldehyde bisulfite, sodium formaldehyde sulfoxylate,
carbon disulfide, sulfur, potassium iodide, potassium cyanide,
hydroquinone, phenol, t-butanol, ethylene glycol, methanol,
butyraldehyde, glyoxal and the like. Preferably, the reducing agent
is sodium formate at a concentration of about 66 to 150 ppm.
36. IX resin elution may be a multistage process. Preferably, all
IX resin elution stages are performed at an elevated temperature
sufficient to reduce barium sulfate, calcium fluoride and iron
silicate precipitation, preferably between about 170 to 230.degree.
F. and more preferably 190 to 210.degree. F. Maintaining the
temperature at these levels reduces the possibility of thermal
shock to the resin and to reduce precipitation. Care must also be
taken to avoid overheating in any IX loading, resin loading or
elution stage. If the column format is used, the temperature must
be controlled to avoid flashing within the column, which can
introduce voids through steam generation and disrupt the
performance of the resin elution process.
37. Control of column operating pressure is important to preserve
the integrity, operating life and longevity of the IX resin.
Preferably, the pressure drop across the column is less than 10
pounds per square inch (psi) during loading, washing, backwashing
and eluting operations. Greater pressure drop may result in resin
bead damage, leading to reduced yields and increased operating
costs.
38. The following is a description of each stage of the preferred
elution sequence.
39. Stage 1A1 (see FIG. 1) is a salt wash which is designed to
remove residual geothermal brine from the IX column prior to
elution in order to control calcium, iron and other ions entering
the IX product streams. Stripping zinc during this stage is
prevented by maintaining a high level of chloride in the solution.
Sodium formate is added to this solution to control ferric iron
precipitation. To achieve this, recycled raffinate is mixed with
crystalline salt in a salt wash tank which is provided with a steam
coil to keep the desired temperature of 190.degree. F. The
raffinate/salt mixture is fed to the column and its destination
after exiting the column is the raffinate tank. From the raffinate
tank, the solution is pumped into the brine feed at a constant rate
for the remainder of the elution sequence.
40. Preferably the wash solution is about 0.5 to 1 bed volumes,
more preferably about 0.7 bed volumes. In this context, bed volume
means total bed volume which is the excluded volume plus the void
volume. The IX resin is preferably washed with an aqueous acidic
sodium chloride solution at 190.degree. F. Preferably the pH of the
wash solution is about 2.0 and the sodium chloride concentration is
from about 1% to about 4% sodium chloride, more preferably 2.5%
sodium chloride (0.3 to 1.0 M, more preferably 0.5 M). Use of the
aqueous acidic sodium chloride solution in the wash stage allows
for separation of zinc from other ions such as iron as the zinc
chloride complex is held tightly by the resin. Other ions
physically present in the brine and not strongly associated with
the resin such as calcium and barium are removed through this
washing step.
41. A reducing agent, preferably sodium formate, may be added to
any of the IX column solutions. Preferably, the reducing agent is
at least added to the solutions used for Stage 1A1 and in any
re-equilibration steps, and is also preferably added to the
solution for Stage 1A. In the case that sodium formate is added, a
sodium formate concentration of about 66 to 500 ppm is preferred,
more preferably about 60 to 150 ppm.
42. The elution flow rate through resin is between 0.25:1 and 0.5:1
bed volumes per minute (BV/m). For example, when the bed volume is
72 gallons and the elution flow rate is 0.5 BV/m, the flow rate is
36 gpm.
43. Stage 1A (see FIG. 2), a blowdown stage, is a further wash
cycle designed to remove the salt wash solution from the column as
well as any remaining geothermal brine not removed during the salt
wash. Fresh eluant is used which causes some zinc stripping from
the resin. The eluant from this stage is preferably recycled onto
the column in a later cycle. For example, the eluant from this
stage can be directed to a blowdown tank, the contents of which are
mixed with fresh brine prior to IX processing.
44. Stage 1B (see FIG. 3) is used to prepare the column for
producing product eluate. Its purpose is to wash the remaining
fresh eluant from the preceding cycle from the column and replace
it with rich recycle coming from a rich recycle tank. The
destination of the eluant after exiting the column is also a
raffinate tank. Elution is preferably performed with high quality,
low (i.e., .ltoreq.25 ppm) total dissolved salts (TDS) water. In
one preferred embodiment, the elution is performed using "rich
recycle eluate" and "lean recycle eluate" in a controlled sequence.
The eluates are recycled from a previous elution cycle. The pH of
the elution water is preferably less than about pH 2. The elution
water is also preferably de-aerated or de-oxygenated prior to use.
De-aeration or de-oxygenation may be accomplished by any method
known in the art, such as steam flashing, heating and vacuum
de-aeration, and reverse osmosis, and is preferably accomplished by
physical rather than chemical processes. De-aeration or
de-oxygenation of the elution solution reduces scaling of the IX
resin by ferric iron and ferric silicate deposition.
45. Stage 1C (see FIG. 4) is the main product cycle for each mode.
The source of eluant is a rich recycle tank and the volume varies
with the amount of zinc present on the resin. The destination of
the eluate is the IX product tank.
46. In Stage 2A (see FIG. 5), the remaining IX product is washed
into a IX product tank using lean recycle solution from an
intermediate tank.
47. In Stage 2B (see FIG. 6), the column is eluted with lean
recycle. The rich recycle tank is replenished using this solution
from the lean recycle tank. The destination of the eluate after
exiting the column is the rich recycle tank.
48. In Stage 3A (see FIG. 7), fresh eluant with or without HCl
added for pH control is used to wash the remaining solution from
the preceding cycle into the rich recycle tank to complete the
replenishment of the rich recycle tank.
49. In Stage 3B-1 (see FIG. 8), fresh eluate with or without HCl
added for pH control is pumped through the column producing lean
grade zinc solution which is used to replenish the lean recycle
tank.
50. In Stages 3B2, 3B2-1 and 3B2-2 (see FIGS. 9 and 10), fresh
eluant is used continue elution of the IX resin. Stage 3B2-1 (see
FIG. 10), which provides for the removal of total suspended solids
(TSS) which may accumulate in the IX resin during the loading
stage, is a backwash step, in which solution flow is reversed and
wash solution is introduced through the normal column outlet. TSS
removed from the IX resin by backflushing may be collected from the
eluate by any convenient method for removal of solids from aqueous
solutions, such as filtration. In 3B2-1 and 3B2-2, fresh eluant is
used and the eluate is used replenish the lean recycle tank.
51. In Stages 4A, 4B and 4C (see FIGS. 11, 12 and 13), the fresh
eluant tank is replenished with water. Elution must take place at
elevated temperatures to prevent thermal shock to the resin and
precipitation of undesirable solids in the resin bed. Thus, the
water used to fill the fresh eluant tank is heated to a temperature
of 190.degree. F. prior to elution.
52. After the elution cycle, the IX resin is preferably
re-equilibrated in preparation for the next elution cycle. The IX
resin is preferably re-equilibrated with acid water (pH about 2),
optionally including a reducing agent. If a reducing agent is
included in the re-equilibration solution, it is preferably at a
concentration of 66-150 ppm. A preferred reducing agent is sodium
formate.
53. The IX product collected from elution is then purified by
oxidation to remove contaminating metal ions such as iron (Fe),
cadmium (Cd) and lead (Pb). The purification step improves
downstream efficiency. Oxidation may be accomplished by any method
known in the art, such as vigorous aeration or addition of peroxide
and a caustic at moderately elevated temperature. Preferably,
oxidation is accomplished by addition of peroxide, preferably
hydrogen peroxide (H.sub.2O.sub.2) and a caustic, preferably sodium
hydroxide (NaOH) or sodium carbonate, for pH control at a
moderately elevated temperature, preferably 100-170.degree. F.,
more preferably at about 145.degree. F. The oxidized contaminants
may be removed using any method known in the art, such as
filtration, centrifugation, settling/sedimentation, or a
combination thereof.
54. In one preferred embodiment, oxidation is performed by the
addition of hydrogen peroxide (preferably about 0.01 to 0.03 liters
of 50% H.sub.2O.sub.2 per liter of brine) while the pH is
controlled to about 3.7 to 4.3, preferably about pH 4.0. The
oxidation/reduction potential of the oxidation reaction is
preferably controlled to about 380 to 500 mV, more preferably about
400 mV. The oxidized contaminants are preferably removed by
sedimentation and granular media filtration.
55. IX product (or purified IX product) may be used as is, or it
may be concentrated by any method known in the art, such as reverse
osmosis, evaporation, volatilization and the like. The eluate is
preferably concentrated using reverse osmosis (RO). The eluate is
preferably concentrated so as to double the concentration of zinc
in the IX product. Concentration of the IX product is useful to
reduce the size (volume) of subsequent steps in the recovery
process, which reduces capital and operating expense. RO of the IX
product yields an RO permeate (Zn-depleted) and an RO concentrate
(Zn-rich). The Zn-depleted RO permeate can optionally be `recycled`
as a substitute for fresh water in IX resin elution stages.
56. Water-immiscible cationic organic solvent extraction (SX) is
then performed on the IX product. Generally, the SX extractant and
the Zn-containing aqueous (e.g., IX product or RO concentrated IX
product) are mixed, preferably in a countercurrent system, then
allowed to separate into discrete phases. To ensure complete
extraction of Zn from the aqueous, it is preferred that SX is
performed in multiple stages. Preferably, two or more extraction
stages are used, with the aqueous and organic phases in a
countercurrent flow arrangement. The SX extractant is scrubbed to
removed deleterious metals, then stripped.
57. The pH of the aqueous phase should be monitored between each
stage of SX, and adjusted to pH 1 to 3, more preferably about pH 2,
when necessary. Generally, the pH of the aqueous phase will fall
during SX stages, so addition of a caustic is sometimes required.
In commercial operations, addition of caustic is preferably
avoided, to reduce operational costs. Any caustic which will not
interfere with the SX or EW processes is acceptable, including
NaOH, a high grade lime, ammonia, sodium carbonate, and dross from
Zn casting house operations (which includes ammonium chloride, zinc
oxide and zinc metal).
58. The SX may be performed using any water-immiscible cationic
organic chelating agent known in the art. Di-(2-ethylhexyl)
phosphoric acid (D2EHPA) is a preferred SX extractant. The SX
extractant may be diluted prior to use with any diluent known in
the art to be acceptable. If the SX extractant is D2EHPA, a
preferred diluent is kerosene, more preferably a low aromatic
kerosene such as SX11, a hydrocarbon mixture of C.sub.13-C.sub.17
isoalkanes. In a countercurrent arrangement, the SX organic (SX
extractant plus diluent, if used) is mixed with the Zn-containing
aqueous to extract the Zn from the aqueous into the SX organic,
resulting in a Zn-loaded SX organic phase and a Zn-depleted aqueous
phase (SX raffinate). The overall ratio of SX organic to
Zn-containing aqueous is preferably between about 1:3 and 3: 1,
more preferably about 1: 1, and it is preferred that about a 1:1
ratio is maintained in the mixing stage. Following mixing, the two
phases are separated. Preferably, the extraction process is carried
out in multiple stages.
59. The use of mixer settler units with separate mixing and
settling compartments is preferred for SX stages because it allows
recycling of either of the phases from the settling cell(s) to the
mixing cell(s). Such recycling reduces process volume, thereby
reducing costs associated with the process. Mixer settler units may
contain multiple mixing and settling compartments, to allow
multiple stages of extraction, scrubbing, washing, stripping, and
the like.
60. In a preferred embodiment, each stage of SX is carried out in a
mixer settler which contains separate mixing and settling
compartments, and utilizes recycling between mixing and settling
compartments to maintain the organic:aqueous ratio at about 1:1. In
this embodiment, extraction is preferably carried out in four
stages.
61. The pH of the aqueous phase should be monitored between
extraction stages, as the pH may drop to below 1. Preferably, the
pH of the aqueous phase is maintained at about pH 2 to maximize the
efficiency of the D2EHPA reagent for zinc.
62. The SX raffinate may optionally be concentrated, preferably by
RO, to yield a Zn-depleted acid solution, which may be used in
acidification of brine fed to IX, or for other uses such as
acidification of brine feed for any associated facilities which
utilize brine, such geothermal power production plants.
63. Acidified water, preferably acidified with HCl to about pH 2,
is used as a scrubbing solution. Scrubbing is performed by mixing
of the scrubbing solution and the Zn-loaded SX, preferably in a
countercurrent flow arrangement. Scrubbing solution is used at an
overall ratio of preferably 1:20 to 1:1 (scrubbing
solution:Zn-loaded SX organic), more preferably about 1:20 to 1:
10, more preferably about 1:15. After mixing, the two phases are
separated. As with the extraction stages, scrubbing is preferably
performed in more than one stage.
64. Preferably, a mixer settler unit is utilized for scrubbing,
with recycling of the aqueous phase from the settling
compartment(s) to the mixing compartment(s), such that the ratio of
scrubbing solution to Zn-loaded SX organic in the mixing cell is
about 1:3 to 3: 1, more preferably about 1:1. In this embodiment,
scrubbing is preferably accomplished in two stages.
65. After the first scrubbing stage, the SX organic is washed to
remove residual HCl from the organic prior to the stripping stage.
This wash step limits the carryover of chloride ion to the
stripping stage. Washing is preferably carried out with clean
water, such as RO water, at a ratio of about 1:10 to 1:20 (wash
water:Zn-loaded SX organic). In one preferred embodiment, the
washing is carried out in a mixer settler unit with separate mixing
and settling compartments, with recycling of the wash water from
the settling compartment to the mixing compartment to maintain a
wash water:Zn-loaded SX organic ratio of about 1:3 to 3: 1, more
preferably 1: 1, in the mixing cell.
66. The scrubbed SX organic is then stripped. Stripping is
accomplished by mixing countercurrent flows of scrubbed SX organic
and an acid, preferably sulfuric acid (preferably about 150 to 190
g/l sulfuric acid), yielding a stripped SX phase and a Zn-loaded
electrolyte phase. Stripping is preferably performed at an overall
ratio of about 1:1 to 1: 15, more preferably 1:5 to 1:10 (acid:SX
organic). Stripping is also preferably accomplished in more than
one stage.
67. In a preferred embodiment, stripping is performed in a mixer
settler with separate mixing and settling compartments, with
recycling of the acid from the settling compartment(s) to the
mixing compartment(s) to maintain a ratio of 1 :1 (acid:organic) in
the mixing compartment. In this embodiment, stripping is
accomplished in two stages.
68. Stripping the SX organic with sulfuric acid may extract metal
ions other than Zn, such as calcium (Ca). Calcium sulfate may be
precipitated from the Zn-loaded electrolyte by lowering the
temperature of the Zn-loaded electrolyte to the point that the
solution become supersaturated in calcium sulfate, then adding
calcium sulfate seed crystals. The precipitated calcium sulfate may
be removed by filtration, centrifugation, settling/sedimentation,
combinations thereof, or any other method known in the art.
69. Preferably, the stripped SX organic is reused for extraction of
IX eluate. When stripped SX organic is reused, it is preferable to
periodically regenerate the SX organic by extraction with 6 molar
(M) HCl. 6 M HCl extraction is useful for removing any residual
amounts of zinc in addition to iron and minor contaminant metals
such as cadmium that are not extracted in the stripping process.
The regeneration is preferably performed at an overall ratio of
about 15:1 to 1:1 (v/v organic:aqueous), more preferably at an
overall ratio of about 10:1. The necessity for regeneration of
stripped SX organic will be apparent to those skilled in the art,
and can be recognized by reduced organic extraction performance.
Additionally, SX organic with high iron loads can appear orange in
color.
70. Preferably, regeneration of SX organic is performed in a dual
cell extraction unit, with recycling of the acid from the settling
cell to the mixing cell, such that the ratio of acid to SX organic
is about 1:3 to 3: 1, more preferably about 1:1.
71. The Zn-loaded electrolyte may now be used for electrowinning of
Zn metal from the solution. The electrowinning may be performed
using parameters known to those of skill in the art. One preferred
method of electrowinning employs a lead/silver anode and an
aluminum cathode. The addition of a minimal amount of meta/para
creosol may optionally be added for sulfuric acid mist (SAM)
control. An effective amount of an animal glue is added for zinc
plating morphology control. These organic additives when employed
are added in minimal amounts to minimize their adverse effects on
electrowinning current efficiency. In a preferred method for
controlling SAM, polypropylene balls are used to cover the
electrowinning chamber.
72. The zinc thus recovered is substantially pure. Substantially
pure zinc is preferably at least 90%, 95%, 97%, or 99% pure, more
preferably at least 99.9% pure, even more preferably at least
99.99% pure.
EXAMPLES
Example 1
73. The zinc extraction process was tested in a Demonstration Plant
located at the site of a geothermal well facility that is used for
electricity production. The demonstration plant utilizes three main
processes, ion exchange (IX) chromatography, cationic solvent
extraction (SX) and electrowinning. The IX process used three
columns in a continuous process: one column was eluted while the
other two columns were loaded (the loading columns were linked in
series, so the first column in the series was the "lead" column and
the second column was the "tail" column). After elution was
completed, the eluted column was switched to the tail loading
position, the lead loading column was eluted, and the tail loading
column became the lead loading column.
74. Hot (220.degree. F.) clarified, post-flash brine, pH controlled
to 3.3-3.5, containing alkylaminophosphonate (added to inhibit
barium sulfate and calcium fluoride scaling), with an average zinc
grade of 650 mg/L was used as the zinc source. The brine was passed
through a 23.875".times.68" column containing Dowex 21K XLT anion
exchange resin (Dow Chemical Co.) at a flow rate of 42 gallons per
minute (gpm).
75. The resin was loaded by passage of a total of 1431 gallons
(batch volume) of flashed brine, then washed and eluted in a series
of stages (solutions used for wash and elution stages were heated
to 190.degree. F. unless otherwise noted). The desired volume is
determined by (i) the grade of the flashed brine, (ii) active
loading of zinc on resin, and (iii) the volume of resin/column.
76. Stage 1A1--The column was washed with 0.7 bed volumes of wash
solution of 2.5% NaCl (0.3 M) and 150 ppm sodium formate in
raffinate, pH 2. Raffinate is a zinc-stripped acidic water recycled
from the solvent extraction step (below). The column flow-through
("blowdown") was recycled back to the lead load column for recovery
of contained zinc.
77. Stage 1A--The column was then washed with a further 1 bed
volumes of water to remove residual salt. The blowdown was directed
to the two columns in loading phase.
78. Stage 1B--0.6 bed volumes of "rich recycle eluate" (RRE) which
is collected in a RRC tank reserved from Stage 3A, was introduced
into the column to flush the void volume of the wash solution from
Stage 1A out of the column. The void volume of acidic water was
(void volume blowdown) was directed to the two columns in loading
phase. At the end of the void volume blowdown the zinc-rich eluate
was collected in a IX product tank.
79. Stage 1C--2.4 bed volumes of RRE was introduced into the column
to further flush out the column. The eluate was directed to the IX
product tank.
80. Stage 2A--0.7 bed volumes of "lean recycle eluate" (LRE) was
used to complete stripping (elution) of zinc from the IX resin.
Lean recycle eluate is reserved blowdown from Stages 3B1 and 3B2 of
a previous elution cycle. The blowdown from this Stage ("IX
product") was also directed to the IX product tank.
81. Stage 2B--2.5 bed volumes of LRE was used to rinse the IX
column. The eluate was directed to the RRE tank for use in a future
elution cycle.
82. Stage 3A--0.5 bed volumes of fresh eluate (water with added HCl
to pH 2) was used to rinse the IX column. The blowdown from this
Stage was directed to the rich recycle eluate tank, for use in a
future elution cycle.
83. Stage 3B1--0.6 bed volumes of fresh eluate was used to further
rinse the IX column. Blowdown from this Stage was directed to the
lean recycle eluate tank.
84. Stage 3B2--approximately 2.1 bed volumes of fresh eluant were
used to backflush the column (i.e., it was introduced through the
normal outlet) to remove deposited solids. The backflushed solids
were removed by filtration and the filtered backflush solution was
directed to the lean recycle eluate tank.
85. Stage B2-1--approximately 0.5 bed volumes of fresh eluant
(containing 100 ppm sodium formate, with HCl added to a pH of
approximately 2) were introduced through the column inlet to
precondition the column for the next loading cycle.
86. The IX product was then treated to remove iron. The IX product
was pumped through an in-line heater at a controlled flow rate of 5
gpm, where it was heated to 170.degree. F., then into the iron
removal tanks. Hydrogen peroxide (H.sub.2O.sub.2) was added at a
rate of 0.03 grams 50% hydrogen peroxide per liter of IX product
processed, and sodium hydroxide (NaOH) was added to control the pH
to 3.7-3.8. The solution was mechanically agitated in the tanks.
Precipitated iron was removed by a plate frame filter press and the
filtrate was polished by passing the filtrate through a series of
polishing, cartridge filters designed to remove particles larger
than 1 .mu.m. Two filter presses were in parallel with one on
standby at any time.
87. The IX product was cooled using a heat exchanger to less than
110.degree. F., then concentrated approximately 2 fold by reverse
osmosis (RO). Laboratory experiments demonstrated that the permeate
from the RO process could be recycled for use in the IX
process.
88. Zinc was extracted from the RO concentrate by solvent
extraction (SX) using the water-immiscible cationic organic
extractant di-(2-ethylhexyl) phosphoric acid (D2EHPA) dissolved in
kerosene (SX11) as a diluent. Zinc was extracted from the aqueous
RO concentrate with the organic phase (SX organic: 40% D2EHPA, 60%
SX11) using four stage countercurrent process. With extraction
stage, the zinc-poor aqueous phase and the zinc-loaded SX organic
were passed into a settling cell where they separated. The
extraction process involves the intimate mixing of the SX organic
phase and aqueous phase in a mixer box. The mixed phase then
overflows and gravitates to a settling cell. To assist with
separation, the settling cell had a coalescer plate and picket
fence installed. The raffinate (the last zinc-depleted aqueous
phase from the last SX extraction stage) was passed through a
coalescing tower, dual media filter (anthracite and granite) and an
activated carbon column (the Spintek.TM. System, Spintek,
Escondido, Calif.) to remove any trace organic solvent, forming a
raffinate.
89. The zinc-loaded SX organic was then scrubbed at a flow rate of
0.25 gpm with water acidified with HCl (pH 1 to 2) at a ratio of
1:1, acidified RO to SX organic, in the mixing cell in a two stage
countercurrent process using the same method as used for the
extraction process. Scrub raffinate combines with the aqueous RO
concentrate feed to the SX circuit and is fed to the first extract
stage.
90. The scrubbed, zinc-loaded SX organic was stripped in a two
stage countercurrent process using spent electrolyte, 160-170 g/L
sulfuric acid at a flow rate of 0.5 gpm which is derived from the
electrowinning process described below, regenerating the
electrolyte. The fresh electrolyte was then treated to reduce the
concentration of dissolved calcium sulfate, in order to eliminate
problems from gypsum scaling in downstream operations. All of the
regenerated electrolyte was diverted to the gypsum removal system,
where the temperature of the fresh electrolyte was lowered to about
86.degree. F. in a reactor and calcium sulfate seed crystals were
added. The calcium sulfate reactor was followed by a clarifier. The
precipitated gypsum separated with the clarifier was recycled back
to the reactor as seed. The clarifier overflow, fresh electrolyte
as treated by passage through a bank of screen coalescers and dual
media filters (anthracite and garnet) and a bank of activated
carbon columns (Spintek.TM. System) to remove any residual organic
as well as any gypsum precipitates.
91. The fresh electrolyte was then used in an electrowinning (EW)
process to plate out high quality zinc metal. Electrowinning was
carried out in a single cell with three aluminum cathodes and
lead/silver alloy anodes spaced at about 90 mm. Acid mist
suppressant polypropylene spheres covered the EW cell contents. The
EW process was carried out at constant current, and the controller
was set to maintain the current within .+-.5 amps of the target
current density of 420 A/m.sup.2 of plate area. The plate area was
approximately 3 m.sup.2/cathode. The zinc plate was harvested every
48 hours for at least 85% current efficiency or every 24 hours for
at least 90% efficiency. The EW electrolyte was recirculated with
cooling to maintain the temperature at 30-35.degree. C. in the EW
cell. The .DELTA.Zn maintained across the cell was 5 g/L Zn. Spent
electrolyte was recycled for use in SX stripping.
92. The zinc-coated cathodes were removed from the EW cell, rinsed,
then transferred for cathode stripping. The zinc-coated cathodes
were manually stripped.
93. Results from approximately three month-long operating period
are shown in Table 1.
1TABLE 1 Section Criteria Operating Period Units 100 TSS 14.27 ppm
maximum TDS 31.69 % maximum Brine feed grade 655 mg/l Zinc nominal
Availability 94.4 Specific flow 13.37 gpm/sqft Extraction 93.3 %
Zinc contained IX Product Grade 3.958 g/l Zinc Resin loss/breakage
na % maximum Batch Volume 1431 gals IX Product Feed Grade 23.12
mg/l Fe Temp. 150 F Purified IX product (SX 0.29 mg/l Fe feed) 200
Availability 97.5 % Extertainment loss na ppm organic (after
Spintek) Extraction with .about.4 g/l 94.1 % feed Extraction with
.about.8 g/l 91.2 % feed Fresh Electrolyte 93.2 g/l Zinc 300
Availability 96.4 % Current efficiency 77.6 % Zinc Production 205.6
lb./day Zinc Quality 99.99 % Other Gypsum Removal 260 mg/l
Calcium
94. The patents, patent applications, and publications cited
throughout the disclosure are incorporated herein by reference in
their entirety.
95. The present invention has been detailed both by direct
description and by example. Equivalents and modifications of the
present invention will be apparent to those skilled in the art, and
are encompassed within the scope of the invention.
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