Flow mapping of full scale solvent extraction settlers using pulsed Doppler UVP technique

Significance Statement

The current work is a part of a larger Solvent Extraction Technology (SXT) research effort being run by Australia’s CSIRO and varyingly sponsored by numerous multi-national mining and engineering companies. The project until now has provided direct cost savings at several full scale operations including > $ 1 million p.a. at one plant via significant entrainment reduction and thus reduced reagent losses. This was achieved through modified settler and internal furniture design based on knowledge gained from the application of the UVP technology at the plant. Similarly, on a recent greenfield plant, the conventional/standard fence designs were shown to be ineffective where a CSIRO modified design for a similar fence proved highly efficient. The experience, skills and tools of the research team has grown to allow us to now claim world class capability to characterise and understand fluid flow behaviour in Solvent Extraction mixers, settlers and columns matched by proven and predictive CFD modelling capabilities. Refinement of these capabilities continues and industry partners continue to benefit from past and new research outcomes. The work presented here involves a full-scale flow pattern audit, carried out at an operating copper extraction settler. Measurements of this scale have never been achieved before, and showcase CSIRO’s capability to undertake such industrial type campaigns. It also illustrates the complexity of previously assumed “simple” settler flow patterns.

Figure Legend 2D velocity vectors, streamlines and longitudinal velocity contours of the organic layer inside settlers with old (left) and new furniture (right), highlighting the improved flow behaviour obtained with the new furniture.

Chemical Engineering Science, Volume 104, 18 December 2013, Pages 925–933.

K. Mohanarangam ^{a, ,}, W. Yang^a, K.R. Barnard^b, N.J. Kelly^b, D.J. Robinson^b

^a CSIRO Process Science and Engineering/CSIRO Minerals Down Under National Research Flagship, P.O. Box 312, Clayton South, VIC 3169, Australia and

^b CSIRO Process Science and Engineering/CSIRO Minerals Down Under National Research Flagship, P.O. Box 7229, Karawara, WA 6152, Australia.

Abstract

Details behind the experimental technique of ultrasonic velocity profiling (UVP) to obtain in situ velocity measurements of both aqueous and organic phases in commercial solvent extraction Solvent Extraction settlers are presented. The commercial applicability and benefit of the process is demonstrated via the on-site analysis of two settlers at a commercial copper solvent extraction operation. The two settlers had the same dimensions and were operated under essentially equivalent conditions but differed in terms of being assessed before and after routine maintenance, with the internal ‘furniture’ configuration of the latter also being modified. UVP-determined organic and aqueous flow pattern results from the two settlers are reported and compared in relation to the furniture configuration/maintenance status of each. The results highlight the potential for UVP analysis to ascertain flow patterns in commercial solvent extraction settlers to benefit industrial operations directly and to enable the development of improved mathematical (computational fluid dynamics) modelling of flow patterns in settlers.

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Flow mapping of full scale solvent extraction settlers using pulsed Doppler UVP technique

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