Apparatus and Process for the Improved Economic Extraction of Metal from a Metal-Bearing Material

Abstract

The present invention relates to an improved apparatus for economically extracting metal from a metal-bearing material. In particular, the present invention relates to an improved apparatus for extracting metal, including inter alia base metal (i.e. copper) and gold, from a metal-bearing ore, concentrate or other metal-bearing material. The present invention further extends to a process for the extraction of such metal which is carried out in accordance with the aforementioned apparatus. According to a first aspect thereof, the present invention provides an apparatus for extracting metal from a metal-bearing material, said apparatus, including a feed receptacle for receiving a metal-bearing feed stream; a reaction vessel; at least one pump means for delivering the metal-bearing feed stream to the reaction vessel; a means for introducing leaching agents, in the form of a leaching agent solution, to the reaction vessel; a means of agitation by circulating the metal-bearing feed stream and leaching agent solution in the reaction vessel so as to allow for a combination of agitation (tank) leaching and vat leaching to take place; a means for achieving liquid/solid separation; and a means for extracting a metal containing product; —wherein said apparatus is re-locatable and transportable in order to allow the apparatus to be assembled easily on site without being geographically bound to one specific site.

1 . An apparatus for extracting metal from a metal-bearing material, the apparatus comprising:
 a feed receptacle for receiving a metal-bearing feed stream; a reaction vessel; at least one pumping means for delivery of the metal bearing feed stream to the reaction vessel; a means for introducing leaching agents, in the form of a leaching agent solution, to the reaction vessel; a means for agitation and/or stirring and/or circulating the metal-bearing feed stream in the reaction vessel; a means for achieving liquid/solid separation; and a means for extracting a metal-containing product,   wherein said apparatus is re-locatable and transportable in order to allow the apparatus to be assembled easily on site without being geographically bound to one specific site.   
     
     
         2 - 6 . (canceled) 
     
     
         7 . The apparatus according to  claim 1 , wherein the pumping means is a jet pump. 
     
     
         8 . The apparatus of  claim 7 , wherein a centrifugal pump is used as a drive pump for the jet pump. 
     
     
         9 . (canceled) 
     
     
         10 . The apparatus of  claim 7 , wherein the jet pump is configured to achieve mixing of the metal-bearing feed stream and a leaching agent by circulation of these components through the jet pump. 
     
     
         11 - 16 . (canceled) 
     
     
         17 . The apparatus according to  claim 1 , wherein the reaction vessel is configured to receive and process at least 40 tons of dry feed material at a density of 50% solid material. 
     
     
         18 - 22 . (canceled) 
     
     
         23 . The apparatus according to  claim 1 , wherein the pumping means is configured to achieve separation of the reaction vessel constituents into contiguous upper and lower phases. 
     
     
         24 . (canceled) 
     
     
         25 . The apparatus of  claim 23 , wherein a down corner pipe is used to enhance the differential between the two phases. 
     
     
         26 . The apparatus of  claim 23 , comprising a means for achieving liquid/solid separation. 
     
     
         27 - 28 . (canceled) 
     
     
         29 . The apparatus of  claim 26 , wherein an aspect ratio is such that it enhances liquid-solid separation. 
     
     
         30 . The apparatus of  claim 29 , wherein the aspect ratio is between 3.93 to 4.66 H:W. 
     
     
         31 - 33 . (canceled) 
     
     
         34 . The apparatus according to  claim 1 , wherein the apparatus is modular. 
     
     
         35 . The apparatus of  claim 34 , wherein upper and lower sections of the reaction vessel are modular, thereby allowing the reaction vessel to be dismantled and assembled easily on site or at further sites. 
     
     
         36 . The apparatus of  claim 35 , wherein the reaction vessel is skid mounted. 
     
     
         37 . The apparatus according to  claim 1 , wherein the dimensions and configuration of the apparatus are such that they substantially compliment dimensions of a containerized truck. 
     
     
         38 . The apparatus of  claim 37 , wherein the dimensions accord to specific containerized truck dimensions and allow for pre-construction and/or assembly in workshops and/or factories. 
     
     
         39 - 41 . (canceled) 
     
     
         42 . A method for extracting metal from a metal-bearing material wherein said method comprises providing an apparatus of  claim 1 , introducing the metal-bearing material into the apparatus, and extracting the metal from the metal-bearing material. 
     
     
         43 . The method, according to  claim 42 , wherein the metal-bearing material is a metal-bearing ore, metal concentrate, spiral concentrate or tailing that comprises copper, gold, silver, platinum group metals or mixtures thereof. 
     
     
         44 . The method, according to  claim 42 , wherein process water is introduced for start-up conditions. 
     
     
         45 . The method, according to  claim 42 , wherein one or more leaching agents are utilized during the circulation process. 
     
     
         46 . The method, according to  claim 48 , wherein the leaching agent(s) are selected from hydrochloric acid (HCl), sulphuric acid (H 2 SO 4 ), raffinate and iron sulphate (Fe 2 (SO 4 )). 
     
     
         47 . The method, according to  claim 42 , wherein ferric sulphate and oxygen are introduced to accomplish leaching of the metal-bearing material. 
     
     
         48 . The method, according to  claim 42 , wherein a portion of a circulated leaching agent solution is used as a sparging liquid to create a fluidized bed system. 
     
     
         49 . The method, according to  claim 42 , comprising the transfer of washed leaching agent solution to a subsequent process or storage, while remaining solid solution is pumped out to tailings. 
     
     
         50 . The method, according to  claim 42 , wherein reaction of leaching agents and metal-bearing material is carried out under ambient conditions. 
     
     
         51 . The method, according to  claim 42 , wherein the apparatus is assembled at the site where the extraction is performed and/or wherein, upon completion of the extraction, the apparatus is disassembled and transported to a new location where it is re-assembled.