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WO2017109296A1 - A method and an arrangement for monitoring of a metallurgical process in a metallurgical process vessel - Google Patents

A method and an arrangement for monitoring of a metallurgical process in a metallurgical process vessel Download PDF

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Publication number
WO2017109296A1
WO2017109296A1 PCT/FI2016/050922 FI2016050922W WO2017109296A1 WO 2017109296 A1 WO2017109296 A1 WO 2017109296A1 FI 2016050922 W FI2016050922 W FI 2016050922W WO 2017109296 A1 WO2017109296 A1 WO 2017109296A1
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WO
WIPO (PCT)
Prior art keywords
metallurgical
process vessel
ray
metallurgical process
sensor unit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/FI2016/050922
Other languages
French (fr)
Inventor
Erkki Paatero
Kari Saloheimo
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Outotec Finland Oy
Original Assignee
Outotec Finland Oy
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from FI20156031A external-priority patent/FI20156031A7/en
Application filed by Outotec Finland Oy filed Critical Outotec Finland Oy
Publication of WO2017109296A1 publication Critical patent/WO2017109296A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
    • G01N23/02—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material
    • G01N23/04—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and forming images of the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D21/00—Separation of suspended solid particles from liquids by sedimentation
    • B01D21/24—Feed or discharge mechanisms for settling tanks
    • B01D21/2427—The feed or discharge opening located at a distant position from the side walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D21/00—Separation of suspended solid particles from liquids by sedimentation
    • B01D21/30—Control equipment
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
    • C22B3/02—Apparatus therefor
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
    • G01N23/02—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material
    • G01N23/06—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and measuring the absorption
    • G01N23/083—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and measuring the absorption the radiation being X-rays
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
    • G01N23/02—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material
    • G01N23/06—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and measuring the absorption
    • G01N23/10—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and measuring the absorption the material being confined in a container, e.g. in a luggage X-ray scanners
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
    • G01N33/20—Metals
    • G01N33/202—Constituents thereof
    • G01N33/2028—Metallic constituents
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2223/00—Investigating materials by wave or particle radiation
    • G01N2223/30—Accessories, mechanical or electrical features
    • G01N2223/322—Accessories, mechanical or electrical features immerged detecting head
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2223/00—Investigating materials by wave or particle radiation
    • G01N2223/40—Imaging
    • G01N2223/419—Imaging computed tomograph
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2223/00—Investigating materials by wave or particle radiation
    • G01N2223/60—Specific applications or type of materials
    • G01N2223/605—Specific applications or type of materials phases
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2223/00—Investigating materials by wave or particle radiation
    • G01N2223/60—Specific applications or type of materials
    • G01N2223/639—Specific applications or type of materials material in a container
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/20—Recycling

Definitions

  • the present invention relates to the field of mineral engineering and metallurgy and metallurgical technologies in general and to extraction of metal compounds from ores or concentrates by metallurgical processes, and more particularly to a method and an arrangement for monitoring of a metallurgical process in a metallurgical process vessel.
  • Metallurgical technologies are used for obtaining or extracting metal compounds from their ores.
  • Metallurgy is typically divided into four general areas: mineral processing, hydrometallurgy, pyrometallurgy and electrometallurgy-
  • a prior art US Patent application document US 2013/0192351 A1 discloses a typical prior art method and apparatus for determining GVF for aerated fluids and liquids in flotation tanks, columns, drums, tubes, vats.
  • EP 2952259 A1 discloses a typical prior art method and apparatus for froth flotation process using optical measurements.
  • a prior art WO patent application document WO 2014/074002 A1 discloses a typical prior art method and system for the detection of metal inclusions in molten slag.
  • a prior art US Patent document US 7,426,852 B1 discloses a typical prior art submersible meter for measuring a parameter of gas hold-up of a fluid.
  • An object of the present invention is thus to provide a method and an apparatus for implementing the method so as to overcome the above problems and to alleviate the above disadvantages.
  • the objects of the invention are achieved by a method for monitoring of a metallurgical process in a metallurgical process vessel, which the method comprises the steps of:
  • At least one of said at least one X-ray tube and said at least one X-ray sensor unit is arranged inside said metallurgical process vessel.
  • the method comprises the step of controlling said metallurgical process based on the detected X-ray radiation data.
  • the method comprises the step of feeding the metallurgical process vessel with metallurgical process substance.
  • said metallurgical process vessel is a thickener or a clarifier.
  • said metallurgical process vessel is an electrolysis cell.
  • said metallurgical process vessel is a leaching reactor.
  • At least one X-ray tube said at least one X-ray tube being ar- ranged to transmit X-ray radiation into said metallurgical process vessel
  • At least one X-ray sensor unit arranged to detect X-ray radiation travelling inside said metallurgical process vessel
  • sensor data processing unit provides a two- or three dimensional image related to the attenuation of X- rays metallurgical process substance inside said metallurgical process vessel ;
  • At least one of said at least one X-ray tube and at least one X-ray sensor unit is arranged inside said metallurgical process vessel.
  • said arrangement comprises a sensor data processing unit, which said sensor data processing unit controls said metallurgical process based on the detected X-ray radiation data.
  • phase boundaries, distribution of solid content and/or density in the metallurgical process substance inside said metallurgical process vessel is/are calculated based on the detected X-ray radiation data.
  • the gas content and/or the liquid content of the metallurgical process substance at different heights in said metallurgical process vessel is/are calculated based on the detected X-ray radiation data.
  • the distribution and/or content of anode slime in said metallurgical process vessel is calculated based on the detected X-ray radiation data.
  • the crud formation in said metallurgical process vessel is calculated based on the detected X-ray radiation data.
  • the X-rays from said at least one X-ray tube are colli- mated into a narrow beam in at least one dimension when propagating inside said metallurgical process vessel.
  • said at least one X-ray tube is arranged to move or turn in order to transmit X-ray radiation in multiple directions.
  • said at least one X-ray sensor unit is arranged to move or turn.
  • At least one of said at least one X-ray tube and said at least one X-ray sensor unit is attached in a frame structure of said metallurgical process vessel.
  • at least one of said at least one X-ray tube and at least one X-ray sensor unit is attached outside a frame structure of said metallurgical process vessel and that said frame structure is manufac- tured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through said frame structure of said metallurgical dewatering process vessel.
  • At least one of said at least one X-ray tube and at least one X-ray sensor unit is attached outside a frame structure of said metallurgical process vessel and that the frame structure of said metallurgical de- watering process vessel comprises one or more window portions, which said one or more window portions are manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more pref- erably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical dewatering process vessel.
  • said at least one X-ray tube and said least one X-ray sensor unit are realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
  • said metallurgical process vessel is a thickener or a clarifier.
  • said metallurgical process vessel is an electrolysis cell.
  • said metallurgical process vessel is a chemical reactor such as a leaching reactor, a precipitation reactor, a reduction reactor or a synthesis reactor.
  • Figure 1 shows a cross-sectional view of one embodiment of an arrangement for monitoring of a metallurgical dewatering process in a metallurgical process vessel according to the present invention
  • Figure 2 shows a cross-sectional view of another embodiment of an arrangement for monitoring of a metallurgical dewatering process in a metallurgical process vessel according to the present invention
  • Figure 3 shows a cross-sectional view of one embodiment of an arrangement for monitoring of an electrometallurgical process in a metallurgical process vessel according to the present invention
  • Figure 4 shows a cross-sectional view of another embodiment of an arrangement for monitoring of an electrometallurgical process in a metallurgical process vessel according to the present invention
  • Figure 5 shows a cross-sectional view of one embodiment of an arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel according to the present invention
  • Figure 6 shows a cross-sectional view of another embodiment of an arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel according to the present invention.
  • the present invention relates to a method and an arrangement for monitoring of a metallurgical process in a metallurgical process vessel.
  • a metallurgical process vessel is defined as a vessel used in a metallurgical process for holding a metallurgical process substance.
  • a metallurgical process substance is defined as any material in a process stream fed into or out from a metallurgical process, in the form of gas, liquid, particulate solid or any mixture of these.
  • Metallurgical technologies are used for obtaining or extracting metal compounds from their ores.
  • Metallurgy is typically divided into four general areas: mineral processing, hydrometallurgy, pyrometallurgy and electrometallurgy.
  • Mineral processing consists of initially breaking down the ore to smaller sizes depending on the concentration process to be followed, by crushing, grinding, sieving, separation by flotation, magnetic and/or gravity separation, solid-liquid separation by thickening, filtration and water treatment, et cetera.
  • Hydrometallurgical processes involve the use of aqueous chemistry for the recovery of metals from ores, concentrates, and recycled or residual materials by leaching, solution purification, dewatering and recovery technologies, et cetera.
  • Pyrometallurgical processes involve high temperature processes where chemical reactions take place among gases, solids, and molten materials. Electrometallurgy involves processes that take place in some form of electrolytic cell. The most common electrometallurgical processes are electrowinning and electrorefining.
  • Solid-liquid separation processes involve thickening and/or clarifying processes which are carried out in thickeners and/or clarifiers.
  • Thickeners and clarifiers are settling tanks built with mechanical means for continuous removal of solids being deposited by sedimentation.
  • a thickener is generally used to remove valuable solid particulates or valuable suspended solids from liquid for thickening.
  • a clarifier is generally used to remove solid particulates or suspended solids from valuable liquid for clarification. Concentrated particles, collected to the bottom of the tank are known as sludge or slime, while the particles that float to the surface of the liquid are called scum.
  • Leaching involves the use of aqueous solutions, which contain a lix- iviant brought into contact with particulate solid material, part of which is soluble in the lixiviant.
  • aqueous solutions which contain a lix- iviant brought into contact with particulate solid material, part of which is soluble in the lixiviant.
  • leaching process options available for the hydrometallurgical treatment of ores and concentrates. In the leaching process, oxidation potential, temperature, and pH of the solution are important parameters.
  • leaching methods utilizing lixiviants such as sulfuric acid, chloride and cyanide at atmospheric or elevated pressure.
  • Leaching technologies include the leaching of e.g. zinc, copper, nickel, cobalt, gold, silver, molybdenum, uranium, manganese, rare earth elements and synthetic rutile.
  • FIG. 1 shows a cross-sectional view of one embodiment of an arrangement for monitoring of a metallurgical dewatering process in a metallurgical process vessel according to the present invention.
  • a metallurgical process vessel 7 such as a metallurgical dewatering process vessel 7, i.e. a thickener 7, according to the present embodiment is a large container 7 in to which met- allurgical process substance such as metallurgical dewatering process substance, i.e. metallurgical slurry, is fed through a thickener feed inlet 8.
  • Said metallurgical slurry typically also has solid particles.
  • the thickener 7 also comprises an upper central feedwell area 9, into which upper central feedwell area 9 metallurgical slurry is fed and possible dilution water and possible flocculating agent, i.e. flocculant, are added. Said flocculating agent is added for binding the particles in the metallurgical slurry into large flocks. Good flocculant adsorption eliminates the possibility of course/fines segregation and ensures all particles are aggregated together by the flocculant.
  • a metallurgical dewatering process vessel 7 according to the present invention may also act as a clarifier 7.
  • a thickener 7 In a metallurgical dewatering process vessel 7, i.e. a thickener 7, according to the present embodiment has a conical bottom section.
  • the solids settle to the bottom by gravity, also enhanced by a flocculating agent to bind the particles into large flocks.
  • the thickened mass can also be moved toward the bottom centre of the thickener 7 by large rakes (not shown in this embodiment) that rotate around the thickener 7.
  • the overflow from the thickener top outlets 10 in the top of the thickener 7 is a clarified liquid 1 1 .
  • the thickened slurry 12 also called thickener underflow, is pumped out of the thickener bot- torn outlet 13 in the bottom of the thickener.
  • the arrangement for monitoring of a metallurgical dewatering process in a metallurgical dewatering process vessel comprises at least one X-ray tube 18.
  • said at least one X-ray tube 18 is arranged inside said metallurgical dewatering process vessel 7.
  • Said at least one X-ray tube 18 is arranged to transmit X-ray radiation into said metallurgical dewatering process vessel 7.
  • Said X-ray tube 18 is an X-ray tube suitable for X-ray imaging.
  • Said X-ray tube 18 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
  • the arrangement for monitoring of a metallurgical dewatering process in a metallurgical dewatering process vessel comprises at least one X-ray sensor unit 19, said at least one X- ray sensor unit 19 opposing said at least one X-ray tube 18.
  • said at least one X-ray sensor unit 19 is attached at a frame struc- ture of said metallurgical dewatering process vessel 7.
  • Said at least one X-ray sensor unit 19 is arranged to detect X-ray radiation travelling inside said metallurgical process vessel.
  • Said X-ray sensor unit 19 is an X-ray sensor unit suitable for X-ray imaging.
  • Said X-ray sensor unit 19 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that meas- ure the intensity of X-ray radiation.
  • Said at least one X-ray sensor unit 19 may be attached to said frame structure so that said at least one X-ray sensor unit 19 is inside said metallurgical dewatering process vessel 7 or as shown in the Figure 1 so that said at least one X-ray sensor unit 19 is outside said metallurgical dewatering process vessel.
  • the frame structure of said metallurgical dewatering process vessel 7 may be manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical dewatering process vessel 7.
  • the frame structure of said metallurgical dewatering process vessel 7 may comprise one or more window portions, which said one or more window portions are manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical dewatering process vessel 7.
  • Said one or more window portions may be manufactured of polymeric material, glass, aluminium, ceramics or composite.
  • said at least one X-ray sensor unit 19 is arranged inside said metallurgical de- watering process vessel 7 and said at least one X-ray tube 18 is attached at a frame structure of said metallurgical dewatering process vessel 7.
  • the X-rays from said at least one X-ray tube 18 may be colli- mated into a narrow beam in at least one dimension when propagating inside said metallurgical dewatering process vessel 7 thus minimizing the amount of radiation to other directions than the detector. Furthermore, said at least one X-ray tube 18 may be arranged to move or turn in order to transmit X-ray radiation in multiple directions.
  • At least one X-ray sensor unit 19 of said metallurgical dewatering process vessel 7 detects an X-ray radiation transmitted by said opposing at least one X-ray tube unit 18, said X-ray radiation travelling inside said metallurgical dewatering process vessel 7.
  • a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical slurry inside said metallurgical dewatering process vessel 7 based on the detected X-ray radiation data.
  • said at least one X- ray sensor unit 19 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image.
  • Said at least one X-ray tube 18 and the at least one X-ray sensor unit 19 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
  • Said image provided by said at least one X-ray sensor unit 19 gives information for the calculation, monitoring and controlling of process, e.g. metallurgical slurry feed, dilution water and flocculant feed. Furthermore, said image provided by said at least one X-ray sensor unit 19 gives information for the calculation for measurement of the location border between the clarified liquid 1 1 and the settled solids bed, i.e. the settled thickened slurry 12. Furthermore, the gas content and/or the liquid content, e.g. water content of metallurgical slurry at different heights and solids formation in said metallurgical dewatering process vessel 7 may be calculated based on said image provided by said at least one X-ray sensor unit 19.
  • Determining the wa- ter content of the metallurgical slurry online with the help of said image provided by said at least one X-ray sensor unit 19 gives an opportunity to follow the process behaviour, to detect abnormal situations and to make corrective actions in time. Online measurement will also give a long time average measurement result instead of an instantaneous indication.
  • the diameter of the metallurgical dewatering process vessel 7 may range from 5 meters to 100 meters, typically from 10 meters to 40 meters.
  • the bed height of the metallurgical dewatering process vessel 7 may range from 2 meters to 10 meters, typically from 3 meters to 5 meters.
  • FIG. 2 shows a cross-sectional view of another embodiment of an arrangement for monitoring of a metallurgical dewatering process in a metallurgical process vessel according to the present invention.
  • a metallurgical process vessel 7 such as a metallurgical dewatering process vessel 7, i.e. a thick- ener 7, according to the present another embodiment is a large container 7 in to which metallurgical process substance such as metallurgical dewatering process substance, i.e. metallurgical slurry, is fed through a thickener feed inlet 8.
  • Said metallurgical slurry typically also has solid particles.
  • the thickener 7 according to the present another embodiment also comprises an upper central feedwell area 9, into which upper central feedwell area 9 metallurgical slurry is fed and possible dilution water and possible flocculating agent, i.e. flocculant, are added.
  • a metallurgical dewatering process vessel 7 according to the present invention may also act as a clarifier.
  • the solids settle to the bottom also enhanced by a flocculating agent to bind the particles into large flocks.
  • the thickened mass can also be moved toward the bottom centre of the thickener 7 by large rakes (not shown in this embodiment) that rotate around the thickener 7.
  • the overflow from the thickener top outlets 10 in the top of the thickener 7 is a clarified liquid 1 1 .
  • the arrangement for monitoring of a metallurgical dewatering process in a metallurgical dewatering process vessel comprises at least one X-ray tube 20.
  • said at least one X-ray tube 20 is arranged inside said metallurgical dewatering process vessel 7.
  • Said at least one X-ray tube 20 is arranged to transmit X-ray radiation into said metallurgical dewatering process vessel 7.
  • Said X-ray tube 20 is an X-ray tube suitable for X-ray imaging.
  • Said X-ray tube 20 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
  • the arrangement for monitoring of a metallurgical dewatering process in a metallurgical dewatering process vessel comprises at least one X-ray sensor unit 21 , said at least one X-ray sensor unit 21 opposing said at least one X-ray tube 20.
  • said at least one X-ray sensor unit 21 is also arranged inside said metallurgical dewatering process vessel 7.
  • Said at least one X-ray sensor unit 21 is arranged to detect X-ray radiation travelling inside said metallurgical process vessel.
  • Said X-ray sensor unit 21 is an X-ray sensor unit suitable for X-ray imaging.
  • Said X-ray sensor unit 21 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that measure the intensity of X-ray radiation.
  • the X-rays from said at least one X-ray tube 20 may be col- limated into a narrow beam in at least one dimension when propagating inside said metallurgical dewatering process vessel 7 thus minimizing the amount of radiation to other directions than the detector.
  • said at least one X-ray tube 20 may be arranged to move or turn in order to transmit X-ray radia- tion in multiple directions.
  • At least one X-ray sensor unit 21 of said metallurgical dewatering process vessel 7 detects an X-ray radiation transmitted by said opposing at least one X-ray tube unit 20, said X-ray radiation travelling inside said metallurgical dewatering process vessel 7.
  • a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical slurry inside said metallurgical dewatering process vessel 7 based on the detected X-ray radiation data.
  • said at least one X- ray sensor unit 21 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image.
  • Said at least one X-ray tube 18 and the at least one X-ray sensor unit 19 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
  • Said image provided by said at least one X-ray sensor unit 21 gives information for the calculation, monitoring and controlling of process, e.g. metallurgical slurry feed, dilution water and flocculant feed. Furthermore, said im- age provided by said at least one X-ray sensor unit 21 gives information for the calculation for measurement of the location border between the clarified liquid 1 1 and the settled solids bed, i.e. the settled thickened slurry 12.
  • the gas content and/or the liquid content e.g. water content of metallurgical slurry at different heights and solids formation in said metallurgical dewatering process vessel 7 may be calculated based on said image provided by said at least one X-ray sensor unit 21 . Determining the water content of the metallurgical slurry online with the help of said image provided by said at least one X-ray sensor unit 21 gives an opportunity to follow the process behaviour, to detect abnormal situations and to make corrective ac- tions in time. Online measurement will also give a long time average measurement result instead of an instantaneous indication.
  • the diameter of the metallurgical dewatering process vessel 7 may range from 5 meters to 100 meters, typically from 10 meters to 40 meters.
  • the bed height of the metallurgical dewatering process vessel 7 may range from 2 meters to 10 meters, typically from 3 meters to 5 meters.
  • FIG. 3 shows a cross-sectional view of one embodiment of an arrangement for monitoring of an electrometallurgical process in a metallurgical process vessel according to the present invention.
  • a metallurgical process vessel 14 such as an electrometallurgical process vessel 14, i.e. an electrolysis cell 14, according to the present embodiment is a large tank 14 which contains metallurgical process substance 15 such as electrometallurgical process substance 15, i.e. metallurgical liquid solution 15. Said metallurgical liquid solu- tion 15 contains also solid particles, such as valuable metal particles.
  • the electrolysis cell 14 according to the present embodiment also comprises a cathode plate 16.
  • a current is passed from an inert anode through a metallurgical liquid solution 15 to the cathode plate 16.
  • said metallurgical liquid solution 15 contains valuable metal particles so that the valuable metal particles is extracted as it is deposited in an electroplating process onto the cathode plate 16.
  • the thickened slime 17 in the electrolysis cell 14 may cause serious problems in the electrolysis cell 14 as it reaches the bottom of the cathode plate 16.
  • the anode slime 17 in the electrolysis cell 14 has to be removed regularly.
  • the arrangement for monitoring of an electrometallurgical process in an electrometallurgical process vessel comprises at least one X-ray tube 22.
  • said at least one X-ray tube 22 is attached outside said frame structure of said electrometallurgical process vessel 14.
  • Said at least one X-ray tube 22 is arranged to transmit X-ray radiation into said electrometallurgical process vessel 14.
  • Said X-ray tube 22 is an X-ray tube suitable for X-ray imaging.
  • Said X-ray tube 22 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
  • the arrangement for monitoring of an electrometallurgical process in an electrometallurgical process vessel comprises at least one X-ray sensor unit 23, said at least one X-ray sensor unit 23 opposing said at least one X-ray tube 22.
  • said at least one X-ray sensor unit 23 is arranged inside said electrometallurgical process vessel 14.
  • Said at least one X-ray sensor unit 23 is arranged to detect X-ray radiation travelling inside said electrometallurgical process vessel 14.
  • Said X-ray sensor unit 23 is an X-ray sensor unit suitable for X-ray imaging.
  • Said X-ray sensor unit 23 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that measure the intensity of X-ray radiation.
  • said at least one X-ray sensor unit 23 is attached outside said frame structure of said electrometallurgical process vessel 14 and said at least one X-ray tube 22 is arranged inside said electrometallurgical process vessel 14.
  • the X-rays from said at least one X-ray tube 22 may be collimated into a narrow beam in at least one dimension when propagating inside said electrometallurgical process vessel 14 thus minimizing the amount of radiation to other directions than the detector. Furthermore, said at least one X-ray tube 22 may be arranged to move or turn in order to transmit X-ray radiation in multiple di- rections.
  • At least one X-ray sensor unit 23 of said electrometallurgical process vessel 14 detects an X-ray radiation transmitted by said opposing at least one X-ray tube unit 22, said X-ray radiation travelling inside said electrometallurgical process vessel 14.
  • a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical process substance 15 and/or the distribution and/or content of anode slime 17 inside said electrometallurgical process vessel 14 based on the detected X-ray radiation data.
  • said at least one X-ray sensor unit 23 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image.
  • Said at least one X-ray tube 22 and the at least one X-ray sensor unit 23 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
  • Said image provided by said at least one X-ray sensor unit 23 gives information for the calculation, monitoring and controlling of process, e.g. timing of removal of the anode slime 17 in the electrolysis cell 14. Furthermore, said image provided by said at least one X-ray sensor unit 23 gives information for the calculation for measurement of the location border between the metallurgical process substance 15 and the settled and thickened anode slime 17. Determining the location border between the metallurgical process substance 15 and the settled and thickened anode slime 17 with the help of said image provided by said at least one X-ray sensor unit 19 gives an opportunity to follow the process behaviour, to detect abnormal situations and to make corrective actions in time. Online measurement will also give a long time average measurement result instead of an instantaneous indication.
  • FIG. 4 shows a cross-sectional view of another embodiment of an arrangement for monitoring of an electrometallurgical process in a metallurgical process vessel according to the present invention.
  • a metallurgical process vessel 14 such as an electrometallurgical process vessel 14, i.e. an electroly- 5 sis cell 14, according to the present another embodiment is a large tank 14 which contains metallurgical process substance 15 such as electrometallurgical process substance 15, i.e. metallurgical liquid solution 15. Said metallurgical liquid solution 15 contains also solid particles, such as valuable metal particles.
  • the electrolysis cell 14 according to the present another embodiment ali o so comprises a cathode plate 16.
  • a current is passed from an inert anode through a metallurgical liquid solution 15 to the cathode plate 16.
  • said metallurgical liquid solution 15 contains valuable metal particles so that the 15 valuable metal particles is extracted as it is deposited in an electroplating process onto the cathode plate 16.
  • the thickened slime 17 in the electrolysis cell 14 may cause serious problems in the electrolysis cell 14 as it reaches the bottom of the cathode plate 16.
  • the anode slime 17 in the electrolysis cell 14 has to be removed regularly.
  • the arrangement for monitoring of an electrometallurgical process 25 in an electrometallurgical process vessel comprises at least one X-ray tube 24.
  • said at least one X-ray tube 24 is arranged inside said electrometallurgical process vessel 14.
  • Said at least one X-ray tube 24 is arranged to transmit X-ray radiation into said electrometallurgical process vessel 14.
  • Said X-ray 30 tube 24 is an X-ray tube suitable for X-ray imaging.
  • Said X-ray tube 24 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
  • the arrangement for monitoring of an electrometallurgical process in an electrometallurgical process vessel comprises at least one X-ray sensor unit 25, said at least one X-ray sensor unit 25 opposing said at least one X-ray tube 24.
  • said at least one X-ray sensor unit 25 is also arranged inside said electrometallurgical process vessel 14.
  • Said at least one X-ray sensor unit 25 is arranged to detect X-ray radiation travelling inside said electrometallurgical process vessel 14.
  • Said X-ray sensor unit 25 is an X-ray sensor unit suitable for X-ray imaging.
  • Said X-ray sensor unit 25 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that measure the intensity of X-ray radiation.
  • the X-rays from said at least one X-ray tube 24 may be collimated into a narrow beam in at least one dimension when propagating inside said electrometallurgical process vessel 14 thus minimizing the amount of radiation to other directions than the detector. Furthermore, said at least one X-ray tube 24 may be arranged to move or turn in order to transmit X-ray radiation in mul- tiple directions.
  • At least one X-ray sensor unit 25 of said electrometallurgical process vessel 14 detects an X-ray radiation transmitted by said opposing at least one X-ray tube unit 24, said X-ray radiation travelling inside said electrometallurgical process vessel 14.
  • a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical process substance 15 and/or the distribution and/or content of anode slime 17 inside said electrometallurgical process vessel 14 based on the detected X-ray radiation data.
  • said at least one X-ray sensor unit 25 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image.
  • Said at least one X-ray tube 24 and the at least one X-ray sensor unit 25 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
  • Said image provided by said at least one X-ray sensor unit 25 gives information for the calculation, monitoring and controlling of process, e.g. timing of removal of the anode slime 17 in the electrolysis cell 14. Furthermore, said image provided by said at least one X-ray sensor unit 25 gives information for the calculation for measurement of the location border between the metallurgical process substance 15 and the settled and thickened anode slime 17. Determining the location border between the metallurgical process substance 15 and the settled and thickened anode slime 17 with the help of said image provided by said at least one X-ray sensor unit 19 gives an opportunity to follow the process behaviour, to detect abnormal situations and to make corrective actions in time. Online measurement will also give a long time average measurement result instead of an instantaneous indication.
  • FIG. 5 shows a cross-sectional view of one embodiment of an arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel according to the present invention.
  • a metallurgical leaching process vessel 26, i.e. a leaching reactor 26, according to the present embodiment is a large container 26 which contains metallurgical process sub- stance 28 such as metallurgical leaching process substance 28, i.e. metallurgical leach solution 28.
  • Said metallurgical leach solution 28 contains also solid particles, such as valuable metal particles.
  • a metallurgical leaching process vessel 31 comprises a rotating agitator 27, which said rotating agitator 27 mixes and circulates the metallurgical process substance 28 inside the metallurgical leaching process vessel 26.
  • the arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel comprises at least one X-ray tube 29.
  • said at least one X-ray tube 29 is arranged inside said metallurgical leaching process vessel 26.
  • Said at least one X-ray tube 29 is arranged to transmit X-ray radiation into said metallurgical leaching process vessel 26.
  • Said X-ray tube 29 is an X-ray tube suitable for X-ray imaging.
  • Said X-ray tube 29 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
  • the arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel comprises at least one X-ray sensor unit 30, said at least one X-ray sensor unit 30 opposing said at least one X-ray tube 29.
  • said at least one X-ray sensor unit 30 is attached at a frame structure of said metallurgical leaching process vessel 26.
  • Said at least one X-ray sensor unit 30 is arranged to detect X-ray radiation travelling inside said metallurgical process vessel.
  • Said X-ray sensor unit 30 is an X-ray sensor unit suitable for X-ray imaging.
  • Said X-ray sensor unit 30 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that measure the intensity of X-ray radiation.
  • Said at least one X-ray sensor unit 30 may be attached to said frame structure so that said at least one X-ray sensor unit 30 is inside said metallurgical leaching process vessel 26 or as shown in the Figure 5 so that said at least one X-ray sensor unit 30 is outside said metallurgical leaching process vessel.
  • the frame structure of said metallurgical dewater- ing process vessel 7 may be manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical dewatering process vessel 7.
  • the frame structure of said metallurgical leaching process vessel 26 may comprise one or more window portions, which said one or more window portions are manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical leaching process vessel 26.
  • Said one or more window portions may be manufactured of polymeric material, glass, aluminium, ceramics or composite.
  • said at least one X-ray sensor unit 30 is arranged inside said metallurgical leaching process vessel 26 and said at least one X-ray tube 29 is attached at a frame structure of said metallurgical leaching process vessel 26.
  • the X-rays from said at least one X-ray tube 29 may be collimated into a narrow beam in at least one dimension when propagating inside said metallurgical leaching process vessel 26 thus minimizing the amount of radiation to other directions than the detector. Furthermore, said at least one X-ray tube 29 may be arranged to move or turn in order to transmit X-ray radiation in multiple directions.
  • At least one X-ray sensor unit 30 of said metallurgical leaching process vessel 26 detects an X-ray radiation transmitted by said opposing at least one X-ray tube unit 29, said X-ray radiation travelling inside said metallurgical leaching process vessel 26. From said detected X-ray radiation data a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical leaching process substance 28 inside said metallurgical leaching process vessel 26 based on the detected X-ray radiation data.
  • said at least one X-ray sensor unit 30 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image.
  • Said at least one X-ray tube 29 and the at least one X-ray sensor unit 30 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
  • Said image provided by said at least one X-ray sensor unit 30 gives information for the calculation, monitoring and controlling of process, e.g. metallurgical leaching process substance 28 feed, dilution water feed and leaching reagent feed. Furthermore, said image provided by said at least one X-ray sensor unit 30 gives information for the calculation for the progress of the meti s allurgical leaching process and for the characteristics of the metallurgical leaching process substance 28 inside said metallurgical leaching process vessel 26. Furthermore, the gas content and/or the liquid content, e.g. water content of metallurgical slurry at different heights and solids formation in said metallurgical leaching process vessel 26 may be calculated based on said image 20 provided by said at least one X-ray sensor unit 30. Online measurement will also give a long time average measurement result instead of an instantaneous indication.
  • Figure 6 shows a cross-sectional view of another embodiment of an arrangement for monitoring of a metallurgical leaching process in a metallurgi-
  • a metallurgical leaching process vessel 31 i.e. a leaching reactor 31
  • a metallurgical leaching process vessel 31 is a large container 31 which contains metallurgical leaching process substance 34, i.e. metallurgical leach solution 34.
  • Said metallurgical leach solution 34 contains also solid particles, such as valuable metal
  • a metallurgical leaching process vessel 31 comprises two 35 rotating agitators 32, 33, which two rotating agitators 32, 33 mix and circulate the metallurgical process substance 34 inside the metallurgical leaching process vessel 31 .
  • the arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel comprises at least one X-ray tube 35.
  • said at least one X-ray tube 35 is arranged inside said metallurgical leaching process vessel 31 .
  • Said at least one X-ray tube 35 is arranged to transmit X-ray radiation into said metallurgical leaching process vessel 31 .
  • Said X-ray tube 35 is an X-ray tube suitable for X-ray imaging.
  • Said X-ray tube 35 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
  • the arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel comprises at least one X-ray sensor unit 36, said at least one X- ray sensor unit 36 opposing said at least one X-ray tube 35.
  • said at least one X-ray sensor unit 36 is attached at a frame structure of said metallurgical leaching process vessel 31 .
  • Said at least one X-ray sensor unit 36 is arranged to detect X-ray radiation travelling inside said metallurgical process vessel.
  • Said X-ray sensor unit 36 is an X-ray sensor unit suitable for X-ray imaging.
  • Said X-ray sensor unit 36 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that measure the intensity of X-ray radiation.
  • Said at least one X-ray sensor unit 36 may be attached to said frame structure so that said at least one X-ray sensor unit 36 is inside said metallurgical leaching process vessel 31 or as shown in the Figure 6 so that said at least one X-ray sensor unit 36 is outside said metallurgical leaching process vessel.
  • the frame structure of said metallurgical dewater- ing process vessel 7 may be manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical dewatering process vessel 7.
  • the frame structure of said metallurgical leaching process vessel 31 may comprise one or more window portions, which said one or more window portions are manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical leaching process vessel 31 .
  • Said one or more window portions may be manufactured of polymeric material, glass, aluminium, ceramics or composite.
  • said at least one X-ray sensor unit 36 is arranged inside said metallurgical leaching process vessel 31 and said at least one X-ray tube 35 is attached at a frame structure of said metallurgical leaching process vessel 31 .
  • the X-rays from said at least one X-ray tube 35 may be col- limated into a narrow beam in at least one dimension when propagating inside said metallurgical leaching process vessel 31 thus minimizing the amount of radiation to other directions than the detector. Furthermore, said at least one X-ray tube 35 may be arranged to move or turn in order to transmit X-ray radia- tion in multiple directions.
  • At least one X-ray sensor unit 36 of said metallurgical leaching process vessel 31 detects an X-ray radiation transmitted by said opposing at least one X-ray tube unit 35, said X-ray radiation travelling inside said metallurgical leaching process vessel 31 .
  • a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical process substance 34 inside said metallurgical leaching process vessel 31 based on the detected X-ray radiation data.
  • said at least one X-ray sensor unit 36 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image.
  • Said at least one X-ray tube 35 and the at least one X-ray sensor unit 36 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
  • Said image provided by said at least one X-ray sensor unit 36 gives information for the calculation, monitoring and controlling of process, e.g. metallurgical process substance 34 feed, dilution water feed and leaching reagent feed. Furthermore, said image provided by said at least one X-ray sensor unit 36 gives information for the calculation for the progress of the metallurgical leaching process and for the characteristics of the metallurgical process sub- stance 34 inside said metallurgical leaching process vessel 31 . Furthermore, the gas content and/or the liquid content, e.g. the water content of metallurgical slurry at different heights and the formation of solids in said metallurgical leaching process vessel 31 may be calculated based on said image provided by said at least one X-ray sensor unit 36. Online measurement will also give a long time average measurement result instead of an instantaneous indication.
  • the solution for monitoring of a metallurgical process in a metallurgical process vessel provides a continuous measurement of a metallurgical process substance in a metallurgical process vessel, which is highly insensitive to dirt or contamination.
  • the solution for monitoring of a metallurgical process in a metallurgical process vessel accord- ing to the present invention provides reliable, online measurement data for the monitoring of the metallurgical process.
  • the manufacturers and owners of metallurgical processes and metallurgical process vessels will be able to provide metallurgical process vessels with an ar- rangement producing more reliable measurement data for monitoring of a metallurgical process in a metallurgical process vessel.
  • the solution according to the present invention may be utilised in any kind of a metallurgical process vessel within metallurgy.

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Abstract

The present invention relates to the field of mineral engineering and metallurgy and metallurgical technologies in general and to extraction of metal com¬ pounds from ores or concentrates by metallurgical pro¬ cesses, and more particularly to a method and an ar¬ rangement for monitoring of a metallurgical process in a metallurgical process vessel. An arrangement for monitor¬ ing of a metallurgical process in a metallurgical process vessel (7), (14), (26), (31 ) comprises at least one X-ray tube (18), (20), (22), (24), (29), (35), said at least one X- ray tube (18), (20), (22), (24), (29), (35) being arranged to transmit X-ray radiation into said metallurgical process vessel (7), (14), (26), (31 ), and at least one X-ray sensor unit (19), (21 ), (23), (25), (30), (36) arranged to detect X- ray radiation travelling inside said metallurgical process vessel (7), (14), (26), (31 ), and a sensor data processing unit, which said sensor data processing unit provides a two- or three dimensional image related to the attenuation of X-rays metallurgical process substance (15), (28), (34) inside said metallurgical process vessel (7), (14), (26), (31 ); wherein at least one of said at least one X-ray tube (18), (20), (22), (24), (29), (35) and at least one X-ray sen¬ sor unit (19), (21 ), (23), (25), (30), (36) is arranged inside said metallurgical process vessel (7), (14), (26), (31 ).

Description

A METHOD AND AN ARRANGEMENT FOR MONITORING OF A METALLURGICAL PROCESS IN A METALLURGICAL PROCESS VESSEL
FIELD OF THE INVENTION
The present invention relates to the field of mineral engineering and metallurgy and metallurgical technologies in general and to extraction of metal compounds from ores or concentrates by metallurgical processes, and more particularly to a method and an arrangement for monitoring of a metallurgical process in a metallurgical process vessel.
BACKGROUND OF THE INVENTION
Metallurgical technologies are used for obtaining or extracting metal compounds from their ores. Metallurgy is typically divided into four general areas: mineral processing, hydrometallurgy, pyrometallurgy and electrometallurgy-
A prior art US Patent application document US 2013/0192351 A1 discloses a typical prior art method and apparatus for determining GVF for aerated fluids and liquids in flotation tanks, columns, drums, tubes, vats.
A prior art EP Patent application document EP 2952259 A1 discloses a typical prior art method and apparatus for froth flotation process using optical measurements.
A prior art US Patent application document US 2013/0306525 A1 discloses a typical prior art system and method for froth flotation control.
A prior art WO patent application document WO 2014/074002 A1 discloses a typical prior art method and system for the detection of metal inclusions in molten slag.
A prior art US Patent document US 7,426,852 B1 discloses a typical prior art submersible meter for measuring a parameter of gas hold-up of a fluid.
In general, there are several problems with the prior art solutions for monitoring a metallurgical process in a metallurgical process vessel. So far, the measuring solutions are relatively troublesome and difficult to process. The presence of solids has been difficult to detect. Also the measurement reliability with the prior art measuring solutions has not been adequate enough. Previously there has not been any means for the monitoring of accumulation of solids and the scaling of equipment surfaces of a metallurgical process vessel in the metallurgical process. The problem therefore is to find a solution for an adequate method and an arrangement for monitoring of a metallurgical process in a metallurgical process vessel which can provide continuously reliable measurement data.
There is a demand in the market for a method for monitoring of a metallurgical process in a metallurgical process vessel which method would be continuous, reliable and informative measurement when compared to the prior art solutions. Likewise, there is a demand in the market for an arrangement for monitoring of a metallurgical process in a metallurgical process vessel which arrangement would be reliable and informative measurement when compared to the prior art solutions.
BRIEF DESCRIPTION OF THE INVENTION
An object of the present invention is thus to provide a method and an apparatus for implementing the method so as to overcome the above problems and to alleviate the above disadvantages.
The objects of the invention are achieved by a method for monitoring of a metallurgical process in a metallurgical process vessel, which the method comprises the steps of:
- transmitting X-ray radiation into the metallurgical process vessel by at least one X-ray tube;
- detecting X-ray radiation travelling inside said metallurgical process vessel by at least one X-ray sensor unit; and
- providing a two- or three-dimensional image related to the attenuation of X-rays metallurgical process substance inside said metallurgical process vessel based on the detected X-ray radiation data;
wherein at least one of said at least one X-ray tube and said at least one X-ray sensor unit is arranged inside said metallurgical process vessel.
Preferably the method comprises the step of controlling said metallurgical process based on the detected X-ray radiation data. Preferably the method comprises the step of feeding the metallurgical process vessel with metallurgical process substance.
Preferably in the method, said metallurgical process vessel is a thickener or a clarifier. Alternatively in the method, said metallurgical process vessel is an electrolysis cell. Further alternatively in the method, said metallurgical process vessel is a leaching reactor. Furthermore, the objects of the invention are achieved by an arrangement for monitoring of a metallurgical process in a metallurgical process vessel, which arrangement comprises:
- at least one X-ray tube, said at least one X-ray tube being ar- ranged to transmit X-ray radiation into said metallurgical process vessel,
- at least one X-ray sensor unit arranged to detect X-ray radiation travelling inside said metallurgical process vessel, and
- a sensor data processing unit, which said sensor data processing unit provides a two- or three dimensional image related to the attenuation of X- rays metallurgical process substance inside said metallurgical process vessel ;
wherein at least one of said at least one X-ray tube and at least one X-ray sensor unit is arranged inside said metallurgical process vessel.
Preferably, said arrangement comprises a sensor data processing unit, which said sensor data processing unit controls said metallurgical process based on the detected X-ray radiation data.
Preferably, phase boundaries, distribution of solid content and/or density in the metallurgical process substance inside said metallurgical process vessel is/are calculated based on the detected X-ray radiation data. Preferably, the gas content and/or the liquid content of the metallurgical process substance at different heights in said metallurgical process vessel is/are calculated based on the detected X-ray radiation data. Preferably, the distribution and/or content of anode slime in said metallurgical process vessel is calculated based on the detected X-ray radiation data. Preferably, the crud formation in said metallurgical process vessel is calculated based on the detected X-ray radiation data.
Preferably, the X-rays from said at least one X-ray tube are colli- mated into a narrow beam in at least one dimension when propagating inside said metallurgical process vessel. Further preferably, said at least one X-ray tube is arranged to move or turn in order to transmit X-ray radiation in multiple directions. Preferably, said at least one X-ray sensor unit is arranged to move or turn.
Preferably, at least one of said at least one X-ray tube and said at least one X-ray sensor unit is attached in a frame structure of said metallurgical process vessel. Further preferably, at least one of said at least one X-ray tube and at least one X-ray sensor unit is attached outside a frame structure of said metallurgical process vessel and that said frame structure is manufac- tured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through said frame structure of said metallurgical dewatering process vessel. Alternatively, at least one of said at least one X-ray tube and at least one X-ray sensor unit is attached outside a frame structure of said metallurgical process vessel and that the the frame structure of said metallurgical de- watering process vessel comprises one or more window portions, which said one or more window portions are manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more pref- erably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical dewatering process vessel.
Preferably, said at least one X-ray tube and said least one X-ray sensor unit are realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
Preferably in the arrangement, said metallurgical process vessel is a thickener or a clarifier. Alternatively in the arrangement, said metallurgical process vessel is an electrolysis cell. Alternatively in the arrangement, said metallurgical process vessel is a chemical reactor such as a leaching reactor, a precipitation reactor, a reduction reactor or a synthesis reactor. BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows a cross-sectional view of one embodiment of an arrangement for monitoring of a metallurgical dewatering process in a metallurgical process vessel according to the present invention;
Figure 2 shows a cross-sectional view of another embodiment of an arrangement for monitoring of a metallurgical dewatering process in a metallurgical process vessel according to the present invention;
Figure 3 shows a cross-sectional view of one embodiment of an arrangement for monitoring of an electrometallurgical process in a metallurgical process vessel according to the present invention;
Figure 4 shows a cross-sectional view of another embodiment of an arrangement for monitoring of an electrometallurgical process in a metallurgical process vessel according to the present invention;
Figure 5 shows a cross-sectional view of one embodiment of an arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel according to the present invention; and Figure 6 shows a cross-sectional view of another embodiment of an arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel according to the present invention.
In the following, the invention will be described in greater detail by means of preferred embodiments with reference to the accompanying drawings of Figures 1 to 6.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a method and an arrangement for monitoring of a metallurgical process in a metallurgical process vessel. In the context of the present invention a metallurgical process vessel is defined as a vessel used in a metallurgical process for holding a metallurgical process substance. Respectively, in the context of the present invention a metallurgical process substance is defined as any material in a process stream fed into or out from a metallurgical process, in the form of gas, liquid, particulate solid or any mixture of these.
Metallurgical technologies are used for obtaining or extracting metal compounds from their ores. Metallurgy is typically divided into four general areas: mineral processing, hydrometallurgy, pyrometallurgy and electrometallurgy. Mineral processing consists of initially breaking down the ore to smaller sizes depending on the concentration process to be followed, by crushing, grinding, sieving, separation by flotation, magnetic and/or gravity separation, solid-liquid separation by thickening, filtration and water treatment, et cetera. Hydrometallurgical processes involve the use of aqueous chemistry for the recovery of metals from ores, concentrates, and recycled or residual materials by leaching, solution purification, dewatering and recovery technologies, et cetera. Pyrometallurgical processes involve high temperature processes where chemical reactions take place among gases, solids, and molten materials. Electrometallurgy involves processes that take place in some form of electrolytic cell. The most common electrometallurgical processes are electrowinning and electrorefining.
Solid-liquid separation processes involve thickening and/or clarifying processes which are carried out in thickeners and/or clarifiers. Thickeners and clarifiers are settling tanks built with mechanical means for continuous removal of solids being deposited by sedimentation. A thickener is generally used to remove valuable solid particulates or valuable suspended solids from liquid for thickening. Likewise, a clarifier is generally used to remove solid particulates or suspended solids from valuable liquid for clarification. Concentrated particles, collected to the bottom of the tank are known as sludge or slime, while the particles that float to the surface of the liquid are called scum.
Leaching involves the use of aqueous solutions, which contain a lix- iviant brought into contact with particulate solid material, part of which is soluble in the lixiviant. There are a number of leaching process options available for the hydrometallurgical treatment of ores and concentrates. In the leaching process, oxidation potential, temperature, and pH of the solution are important parameters. There are several leaching methods utilizing lixiviants such as sulfuric acid, chloride and cyanide at atmospheric or elevated pressure. Leaching technologies include the leaching of e.g. zinc, copper, nickel, cobalt, gold, silver, molybdenum, uranium, manganese, rare earth elements and synthetic rutile.
Figure 1 shows a cross-sectional view of one embodiment of an arrangement for monitoring of a metallurgical dewatering process in a metallurgical process vessel according to the present invention. A metallurgical process vessel 7 such as a metallurgical dewatering process vessel 7, i.e. a thickener 7, according to the present embodiment is a large container 7 in to which met- allurgical process substance such as metallurgical dewatering process substance, i.e. metallurgical slurry, is fed through a thickener feed inlet 8. Said metallurgical slurry typically also has solid particles. The thickener 7 according to the present embodiment also comprises an upper central feedwell area 9, into which upper central feedwell area 9 metallurgical slurry is fed and possible dilution water and possible flocculating agent, i.e. flocculant, are added. Said flocculating agent is added for binding the particles in the metallurgical slurry into large flocks. Good flocculant adsorption eliminates the possibility of course/fines segregation and ensures all particles are aggregated together by the flocculant. A metallurgical dewatering process vessel 7 according to the present invention may also act as a clarifier 7.
In a metallurgical dewatering process vessel 7, i.e. a thickener 7, according to the present embodiment has a conical bottom section. The solids settle to the bottom by gravity, also enhanced by a flocculating agent to bind the particles into large flocks. The thickened mass can also be moved toward the bottom centre of the thickener 7 by large rakes (not shown in this embodiment) that rotate around the thickener 7. The overflow from the thickener top outlets 10 in the top of the thickener 7 is a clarified liquid 1 1 . The solids settle to the bottom of the metallurgical dewatering process vessel 7 by gravity and the bottom gives thickened slurry 12 of concentrated solids. The thickened slurry 12, also called thickener underflow, is pumped out of the thickener bot- torn outlet 13 in the bottom of the thickener.
The arrangement for monitoring of a metallurgical dewatering process in a metallurgical dewatering process vessel according to the present embodiment comprises at least one X-ray tube 18. In the present embodiment said at least one X-ray tube 18 is arranged inside said metallurgical dewatering process vessel 7. Said at least one X-ray tube 18 is arranged to transmit X-ray radiation into said metallurgical dewatering process vessel 7. Said X-ray tube 18 is an X-ray tube suitable for X-ray imaging. Said X-ray tube 18 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
The arrangement for monitoring of a metallurgical dewatering process in a metallurgical dewatering process vessel according to the present embodiment comprises at least one X-ray sensor unit 19, said at least one X- ray sensor unit 19 opposing said at least one X-ray tube 18. In the present embodiment said at least one X-ray sensor unit 19 is attached at a frame struc- ture of said metallurgical dewatering process vessel 7. Said at least one X-ray sensor unit 19 is arranged to detect X-ray radiation travelling inside said metallurgical process vessel. Said X-ray sensor unit 19 is an X-ray sensor unit suitable for X-ray imaging. Said X-ray sensor unit 19 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that meas- ure the intensity of X-ray radiation.
Said at least one X-ray sensor unit 19 may be attached to said frame structure so that said at least one X-ray sensor unit 19 is inside said metallurgical dewatering process vessel 7 or as shown in the Figure 1 so that said at least one X-ray sensor unit 19 is outside said metallurgical dewatering process vessel. In the latter the frame structure of said metallurgical dewatering process vessel 7 may be manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical dewatering process vessel 7. Alternatively, the frame structure of said metallurgical dewatering process vessel 7 may comprise one or more window portions, which said one or more window portions are manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical dewatering process vessel 7. Said one or more window portions may be manufactured of polymeric material, glass, aluminium, ceramics or composite.
In an alternative embodiment of an arrangement for monitoring of a metallurgical dewatering process in a metallurgical dewatering process vessel said at least one X-ray sensor unit 19 is arranged inside said metallurgical de- watering process vessel 7 and said at least one X-ray tube 18 is attached at a frame structure of said metallurgical dewatering process vessel 7.
In the arrangement for monitoring of a metallurgical dewatering process in a metallurgical dewatering process vessel according to the present embodiment the the X-rays from said at least one X-ray tube 18 may be colli- mated into a narrow beam in at least one dimension when propagating inside said metallurgical dewatering process vessel 7 thus minimizing the amount of radiation to other directions than the detector. Furthermore, said at least one X-ray tube 18 may be arranged to move or turn in order to transmit X-ray radiation in multiple directions.
In the embodiment presented in Figure 1 at least one X-ray sensor unit 19 of said metallurgical dewatering process vessel 7 detects an X-ray radiation transmitted by said opposing at least one X-ray tube unit 18, said X-ray radiation travelling inside said metallurgical dewatering process vessel 7.
From said detected X-ray radiation data a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical slurry inside said metallurgical dewatering process vessel 7 based on the detected X-ray radiation data. Furthermore, said at least one X- ray sensor unit 19 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image. Said at least one X-ray tube 18 and the at least one X-ray sensor unit 19 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
Said image provided by said at least one X-ray sensor unit 19 gives information for the calculation, monitoring and controlling of process, e.g. metallurgical slurry feed, dilution water and flocculant feed. Furthermore, said image provided by said at least one X-ray sensor unit 19 gives information for the calculation for measurement of the location border between the clarified liquid 1 1 and the settled solids bed, i.e. the settled thickened slurry 12. Furthermore, the gas content and/or the liquid content, e.g. water content of metallurgical slurry at different heights and solids formation in said metallurgical dewatering process vessel 7 may be calculated based on said image provided by said at least one X-ray sensor unit 19. Determining the wa- ter content of the metallurgical slurry online with the help of said image provided by said at least one X-ray sensor unit 19 gives an opportunity to follow the process behaviour, to detect abnormal situations and to make corrective actions in time. Online measurement will also give a long time average measurement result instead of an instantaneous indication.
In order to monitor and control the process, e.g. metallurgical slurry feed, dilution water and flocculant feed, it is useful to measure the location of the settled solids bed. The diameter of the metallurgical dewatering process vessel 7 may range from 5 meters to 100 meters, typically from 10 meters to 40 meters. The bed height of the metallurgical dewatering process vessel 7 may range from 2 meters to 10 meters, typically from 3 meters to 5 meters.
Figure 2 shows a cross-sectional view of another embodiment of an arrangement for monitoring of a metallurgical dewatering process in a metallurgical process vessel according to the present invention. A metallurgical process vessel 7 such as a metallurgical dewatering process vessel 7, i.e. a thick- ener 7, according to the present another embodiment is a large container 7 in to which metallurgical process substance such as metallurgical dewatering process substance, i.e. metallurgical slurry, is fed through a thickener feed inlet 8. Said metallurgical slurry typically also has solid particles. The thickener 7 according to the present another embodiment also comprises an upper central feedwell area 9, into which upper central feedwell area 9 metallurgical slurry is fed and possible dilution water and possible flocculating agent, i.e. flocculant, are added. A metallurgical dewatering process vessel 7 according to the present invention may also act as a clarifier. The solids settle to the bottom also enhanced by a flocculating agent to bind the particles into large flocks. The thickened mass can also be moved toward the bottom centre of the thickener 7 by large rakes (not shown in this embodiment) that rotate around the thickener 7. The overflow from the thickener top outlets 10 in the top of the thickener 7 is a clarified liquid 1 1 . The solids settle to the bottom of the metallurgical de- watering process vessel 7 by gravity and the bottom gives thickened slurry 12 of concentrated solids. The thickened slurry 12, also called thickener under- flow, is pumped out of the thickener bottom outlet 13 in the bottom of the thickener.
The arrangement for monitoring of a metallurgical dewatering process in a metallurgical dewatering process vessel according to the present an- other embodiment comprises at least one X-ray tube 20. In the present another embodiment said at least one X-ray tube 20 is arranged inside said metallurgical dewatering process vessel 7. Said at least one X-ray tube 20 is arranged to transmit X-ray radiation into said metallurgical dewatering process vessel 7. Said X-ray tube 20 is an X-ray tube suitable for X-ray imaging. Said X-ray tube 20 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
The arrangement for monitoring of a metallurgical dewatering process in a metallurgical dewatering process vessel according to the present another embodiment comprises at least one X-ray sensor unit 21 , said at least one X-ray sensor unit 21 opposing said at least one X-ray tube 20. In the present embodiment said at least one X-ray sensor unit 21 is also arranged inside said metallurgical dewatering process vessel 7. Said at least one X-ray sensor unit 21 is arranged to detect X-ray radiation travelling inside said metallurgical process vessel. Said X-ray sensor unit 21 is an X-ray sensor unit suitable for X-ray imaging. Said X-ray sensor unit 21 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that measure the intensity of X-ray radiation.
In the arrangement for monitoring of a metallurgical dewatering process in a metallurgical dewatering process vessel according to the present an- other embodiment the X-rays from said at least one X-ray tube 20 may be col- limated into a narrow beam in at least one dimension when propagating inside said metallurgical dewatering process vessel 7 thus minimizing the amount of radiation to other directions than the detector. Furthermore, said at least one X-ray tube 20 may be arranged to move or turn in order to transmit X-ray radia- tion in multiple directions.
In the another embodiment presented in Figure 2 at least one X-ray sensor unit 21 of said metallurgical dewatering process vessel 7 detects an X- ray radiation transmitted by said opposing at least one X-ray tube unit 20, said X-ray radiation travelling inside said metallurgical dewatering process vessel 7.
From said detected X-ray radiation data a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical slurry inside said metallurgical dewatering process vessel 7 based on the detected X-ray radiation data. Furthermore, said at least one X- ray sensor unit 21 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image. Said at least one X-ray tube 18 and the at least one X-ray sensor unit 19 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
Said image provided by said at least one X-ray sensor unit 21 gives information for the calculation, monitoring and controlling of process, e.g. metallurgical slurry feed, dilution water and flocculant feed. Furthermore, said im- age provided by said at least one X-ray sensor unit 21 gives information for the calculation for measurement of the location border between the clarified liquid 1 1 and the settled solids bed, i.e. the settled thickened slurry 12.
Furthermore, the gas content and/or the liquid content, e.g. water content of metallurgical slurry at different heights and solids formation in said metallurgical dewatering process vessel 7 may be calculated based on said image provided by said at least one X-ray sensor unit 21 . Determining the water content of the metallurgical slurry online with the help of said image provided by said at least one X-ray sensor unit 21 gives an opportunity to follow the process behaviour, to detect abnormal situations and to make corrective ac- tions in time. Online measurement will also give a long time average measurement result instead of an instantaneous indication.
In order to monitor and control the process, e.g. metallurgical slurry feed, dilution water and flocculant feed, it is useful to measure the location of the settled solids bed. The diameter of the metallurgical dewatering process vessel 7 may range from 5 meters to 100 meters, typically from 10 meters to 40 meters. The bed height of the metallurgical dewatering process vessel 7 may range from 2 meters to 10 meters, typically from 3 meters to 5 meters.
Figure 3 shows a cross-sectional view of one embodiment of an arrangement for monitoring of an electrometallurgical process in a metallurgical process vessel according to the present invention. A metallurgical process vessel 14 such as an electrometallurgical process vessel 14, i.e. an electrolysis cell 14, according to the present embodiment is a large tank 14 which contains metallurgical process substance 15 such as electrometallurgical process substance 15, i.e. metallurgical liquid solution 15. Said metallurgical liquid solu- tion 15 contains also solid particles, such as valuable metal particles. The electrolysis cell 14 according to the present embodiment also comprises a cathode plate 16. In an electrometallurgical process according to the present embodiment, a current is passed from an inert anode through a metallurgical liquid solution 15 to the cathode plate 16. In an electrometallurgical process according to the present embodiment said metallurgical liquid solution 15 contains valuable metal particles so that the valuable metal particles is extracted as it is deposited in an electroplating process onto the cathode plate 16.
The invaluable solid particles, such as other metals, which during the processing of the target metal have been reduced but not deposited at the cathode, sink by gravity to the bottom of the electrolytic cell 14, where they form a thickened substance referred to as slime 17 or as anode slime 17. The thickened slime 17 in the electrolysis cell 14 may cause serious problems in the electrolysis cell 14 as it reaches the bottom of the cathode plate 16. The anode slime 17 in the electrolysis cell 14 has to be removed regularly.
The arrangement for monitoring of an electrometallurgical process in an electrometallurgical process vessel according to the present embodiment comprises at least one X-ray tube 22. In the present embodiment said at least one X-ray tube 22 is attached outside said frame structure of said electrometallurgical process vessel 14. Said at least one X-ray tube 22 is arranged to transmit X-ray radiation into said electrometallurgical process vessel 14. Said X-ray tube 22 is an X-ray tube suitable for X-ray imaging. Said X-ray tube 22 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
The arrangement for monitoring of an electrometallurgical process in an electrometallurgical process vessel according to the present embodiment comprises at least one X-ray sensor unit 23, said at least one X-ray sensor unit 23 opposing said at least one X-ray tube 22. In the present embodiment said at least one X-ray sensor unit 23 is arranged inside said electrometallurgical process vessel 14. Said at least one X-ray sensor unit 23 is arranged to detect X-ray radiation travelling inside said electrometallurgical process vessel 14. Said X-ray sensor unit 23 is an X-ray sensor unit suitable for X-ray imaging. Said X-ray sensor unit 23 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that measure the intensity of X-ray radiation.
In an alternative embodiment of an arrangement for monitoring of an electrometallurgical process in an electrometallurgical process vessel said at least one X-ray sensor unit 23 is attached outside said frame structure of said electrometallurgical process vessel 14 and said at least one X-ray tube 22 is arranged inside said electrometallurgical process vessel 14.
In the arrangement for monitoring of an electrometallurgical process in an electrometallurgical process vessel according to the present embodiment the X-rays from said at least one X-ray tube 22 may be collimated into a narrow beam in at least one dimension when propagating inside said electrometallurgical process vessel 14 thus minimizing the amount of radiation to other directions than the detector. Furthermore, said at least one X-ray tube 22 may be arranged to move or turn in order to transmit X-ray radiation in multiple di- rections.
In the embodiment presented in Figure 3 at least one X-ray sensor unit 23 of said electrometallurgical process vessel 14 detects an X-ray radiation transmitted by said opposing at least one X-ray tube unit 22, said X-ray radiation travelling inside said electrometallurgical process vessel 14.
From said detected X-ray radiation data a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical process substance 15 and/or the distribution and/or content of anode slime 17 inside said electrometallurgical process vessel 14 based on the detected X-ray radiation data. Furthermore, said at least one X-ray sensor unit 23 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image. Said at least one X-ray tube 22 and the at least one X-ray sensor unit 23 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
Said image provided by said at least one X-ray sensor unit 23 gives information for the calculation, monitoring and controlling of process, e.g. timing of removal of the anode slime 17 in the electrolysis cell 14. Furthermore, said image provided by said at least one X-ray sensor unit 23 gives information for the calculation for measurement of the location border between the metallurgical process substance 15 and the settled and thickened anode slime 17. Determining the location border between the metallurgical process substance 15 and the settled and thickened anode slime 17 with the help of said image provided by said at least one X-ray sensor unit 19 gives an opportunity to follow the process behaviour, to detect abnormal situations and to make corrective actions in time. Online measurement will also give a long time average measurement result instead of an instantaneous indication. Figure 4 shows a cross-sectional view of another embodiment of an arrangement for monitoring of an electrometallurgical process in a metallurgical process vessel according to the present invention. A metallurgical process vessel 14 such as an electrometallurgical process vessel 14, i.e. an electroly- 5 sis cell 14, according to the present another embodiment is a large tank 14 which contains metallurgical process substance 15 such as electrometallurgical process substance 15, i.e. metallurgical liquid solution 15. Said metallurgical liquid solution 15 contains also solid particles, such as valuable metal particles. The electrolysis cell 14 according to the present another embodiment ali o so comprises a cathode plate 16. In an electrometallurgical process according to the present another embodiment, a current is passed from an inert anode through a metallurgical liquid solution 15 to the cathode plate 16. In an electrometallurgical process according to the present another embodiment said metallurgical liquid solution 15 contains valuable metal particles so that the 15 valuable metal particles is extracted as it is deposited in an electroplating process onto the cathode plate 16.
The invaluable solid particles, such as other metals, which during the processing of the target metal have been reduced but not deposited at the cathode, sink by gravity to the bottom of the electrolytic cell 14, where they 20 form a thickened substance referred to as slime 17 or as anode slime 17. The thickened slime 17 in the electrolysis cell 14 may cause serious problems in the electrolysis cell 14 as it reaches the bottom of the cathode plate 16. The anode slime 17 in the electrolysis cell 14 has to be removed regularly.
The arrangement for monitoring of an electrometallurgical process 25 in an electrometallurgical process vessel according to the present another embodiment comprises at least one X-ray tube 24. In the present another embodiment said at least one X-ray tube 24 is arranged inside said electrometallurgical process vessel 14. Said at least one X-ray tube 24 is arranged to transmit X-ray radiation into said electrometallurgical process vessel 14. Said X-ray 30 tube 24 is an X-ray tube suitable for X-ray imaging. Said X-ray tube 24 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
The arrangement for monitoring of an electrometallurgical process in an electrometallurgical process vessel according to the present another em- 35 bodiment comprises at least one X-ray sensor unit 25, said at least one X-ray sensor unit 25 opposing said at least one X-ray tube 24. In the present another embodiment said at least one X-ray sensor unit 25 is also arranged inside said electrometallurgical process vessel 14. Said at least one X-ray sensor unit 25 is arranged to detect X-ray radiation travelling inside said electrometallurgical process vessel 14. Said X-ray sensor unit 25 is an X-ray sensor unit suitable for X-ray imaging. Said X-ray sensor unit 25 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that measure the intensity of X-ray radiation.
In the arrangement for monitoring of an electrometallurgical process in an electrometallurgical process vessel according to the present another em- bodiment the X-rays from said at least one X-ray tube 24 may be collimated into a narrow beam in at least one dimension when propagating inside said electrometallurgical process vessel 14 thus minimizing the amount of radiation to other directions than the detector. Furthermore, said at least one X-ray tube 24 may be arranged to move or turn in order to transmit X-ray radiation in mul- tiple directions.
In the embodiment presented in Figure 4 at least one X-ray sensor unit 25 of said electrometallurgical process vessel 14 detects an X-ray radiation transmitted by said opposing at least one X-ray tube unit 24, said X-ray radiation travelling inside said electrometallurgical process vessel 14.
From said detected X-ray radiation data a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical process substance 15 and/or the distribution and/or content of anode slime 17 inside said electrometallurgical process vessel 14 based on the detected X-ray radiation data. Furthermore, said at least one X-ray sensor unit 25 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image. Said at least one X-ray tube 24 and the at least one X-ray sensor unit 25 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
Said image provided by said at least one X-ray sensor unit 25 gives information for the calculation, monitoring and controlling of process, e.g. timing of removal of the anode slime 17 in the electrolysis cell 14. Furthermore, said image provided by said at least one X-ray sensor unit 25 gives information for the calculation for measurement of the location border between the metallurgical process substance 15 and the settled and thickened anode slime 17. Determining the location border between the metallurgical process substance 15 and the settled and thickened anode slime 17 with the help of said image provided by said at least one X-ray sensor unit 19 gives an opportunity to follow the process behaviour, to detect abnormal situations and to make corrective actions in time. Online measurement will also give a long time average measurement result instead of an instantaneous indication.
Figure 5 shows a cross-sectional view of one embodiment of an arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel according to the present invention. A metallurgical leaching process vessel 26, i.e. a leaching reactor 26, according to the present embodiment is a large container 26 which contains metallurgical process sub- stance 28 such as metallurgical leaching process substance 28, i.e. metallurgical leach solution 28. Said metallurgical leach solution 28 contains also solid particles, such as valuable metal particles.
In the metallurgical leaching process according to the present embodiment there may be leaching reagents are added to the leaching reactor 26 to achieve a proper leaching reaction. A metallurgical leaching process vessel 31 according to the present embodiment comprises a rotating agitator 27, which said rotating agitator 27 mixes and circulates the metallurgical process substance 28 inside the metallurgical leaching process vessel 26.
The arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel according to the present embodiment comprises at least one X-ray tube 29. In the present embodiment said at least one X-ray tube 29 is arranged inside said metallurgical leaching process vessel 26. Said at least one X-ray tube 29 is arranged to transmit X-ray radiation into said metallurgical leaching process vessel 26. Said X-ray tube 29 is an X-ray tube suitable for X-ray imaging. Said X-ray tube 29 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
The arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel according to the present embodi- ment comprises at least one X-ray sensor unit 30, said at least one X-ray sensor unit 30 opposing said at least one X-ray tube 29. In the present embodiment said at least one X-ray sensor unit 30 is attached at a frame structure of said metallurgical leaching process vessel 26. Said at least one X-ray sensor unit 30 is arranged to detect X-ray radiation travelling inside said metallurgical process vessel. Said X-ray sensor unit 30 is an X-ray sensor unit suitable for X-ray imaging. Said X-ray sensor unit 30 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that measure the intensity of X-ray radiation.
Said at least one X-ray sensor unit 30 may be attached to said frame structure so that said at least one X-ray sensor unit 30 is inside said metallurgical leaching process vessel 26 or as shown in the Figure 5 so that said at least one X-ray sensor unit 30 is outside said metallurgical leaching process vessel. In the latter the frame structure of said metallurgical dewater- ing process vessel 7 may be manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical dewatering process vessel 7. Alternatively, the frame structure of said metallurgical leaching process vessel 26 may comprise one or more window portions, which said one or more window portions are manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical leaching process vessel 26. Said one or more window portions may be manufactured of polymeric material, glass, aluminium, ceramics or composite.
In an alternative embodiment of an arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel said at least one X-ray sensor unit 30 is arranged inside said metallurgical leaching process vessel 26 and said at least one X-ray tube 29 is attached at a frame structure of said metallurgical leaching process vessel 26.
In the arrangement for monitoring of a metallurgical leaching pro- cess in a metallurgical leaching process vessel according to the present embodiment the X-rays from said at least one X-ray tube 29 may be collimated into a narrow beam in at least one dimension when propagating inside said metallurgical leaching process vessel 26 thus minimizing the amount of radiation to other directions than the detector. Furthermore, said at least one X-ray tube 29 may be arranged to move or turn in order to transmit X-ray radiation in multiple directions.
In the embodiment presented in Figure 5 at least one X-ray sensor unit 30 of said metallurgical leaching process vessel 26 detects an X-ray radiation transmitted by said opposing at least one X-ray tube unit 29, said X-ray radiation travelling inside said metallurgical leaching process vessel 26. From said detected X-ray radiation data a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical leaching process substance 28 inside said metallurgical leaching process vessel 26 based on the detected X-ray radiation data. Fur- 5 thermore, said at least one X-ray sensor unit 30 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image. Said at least one X-ray tube 29 and the at least one X-ray sensor unit 30 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
10 Said image provided by said at least one X-ray sensor unit 30 gives information for the calculation, monitoring and controlling of process, e.g. metallurgical leaching process substance 28 feed, dilution water feed and leaching reagent feed. Furthermore, said image provided by said at least one X-ray sensor unit 30 gives information for the calculation for the progress of the meti s allurgical leaching process and for the characteristics of the metallurgical leaching process substance 28 inside said metallurgical leaching process vessel 26. Furthermore, the gas content and/or the liquid content, e.g. water content of metallurgical slurry at different heights and solids formation in said metallurgical leaching process vessel 26 may be calculated based on said image 20 provided by said at least one X-ray sensor unit 30. Online measurement will also give a long time average measurement result instead of an instantaneous indication.
Figure 6 shows a cross-sectional view of another embodiment of an arrangement for monitoring of a metallurgical leaching process in a metallurgi-
25 cal leaching process vessel according to the present invention. A metallurgical leaching process vessel 31 , i.e. a leaching reactor 31 , according to the present another embodiment is a large container 31 which contains metallurgical leaching process substance 34, i.e. metallurgical leach solution 34. Said metallurgical leach solution 34 contains also solid particles, such as valuable metal
30 particles.
In the metallurgical leaching process according to the present another embodiment there may be leaching reagents are added to the leaching reactor 31 to achieve a proper leaching reaction. A metallurgical leaching process vessel 31 according to the present another embodiment comprises two 35 rotating agitators 32, 33, which two rotating agitators 32, 33 mix and circulate the metallurgical process substance 34 inside the metallurgical leaching process vessel 31 .
The arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel according to the present another embodiment comprises at least one X-ray tube 35. In the present another embodiment said at least one X-ray tube 35 is arranged inside said metallurgical leaching process vessel 31 . Said at least one X-ray tube 35 is arranged to transmit X-ray radiation into said metallurgical leaching process vessel 31 . Said X-ray tube 35 is an X-ray tube suitable for X-ray imaging. Said X-ray tube 35 may have a point focus and may be equipped with a collimator that limits the X-ray beam to a desired direction.
The arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel according to the present another embodiment comprises at least one X-ray sensor unit 36, said at least one X- ray sensor unit 36 opposing said at least one X-ray tube 35. In the present another embodiment said at least one X-ray sensor unit 36 is attached at a frame structure of said metallurgical leaching process vessel 31 . Said at least one X- ray sensor unit 36 is arranged to detect X-ray radiation travelling inside said metallurgical process vessel. Said X-ray sensor unit 36 is an X-ray sensor unit suitable for X-ray imaging. Said X-ray sensor unit 36 may comprise at least two, preferably more than 31 , more preferably more than 127, detectors that measure the intensity of X-ray radiation.
Said at least one X-ray sensor unit 36 may be attached to said frame structure so that said at least one X-ray sensor unit 36 is inside said metallurgical leaching process vessel 31 or as shown in the Figure 6 so that said at least one X-ray sensor unit 36 is outside said metallurgical leaching process vessel. In the latter the frame structure of said metallurgical dewater- ing process vessel 7 may be manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical dewatering process vessel 7. Alternatively, the frame structure of said metallurgical leaching process vessel 31 may comprise one or more window portions, which said one or more window portions are manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical leaching process vessel 31 . Said one or more window portions may be manufactured of polymeric material, glass, aluminium, ceramics or composite.
In an alternative embodiment of an arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel said at least one X-ray sensor unit 36 is arranged inside said metallurgical leaching process vessel 31 and said at least one X-ray tube 35 is attached at a frame structure of said metallurgical leaching process vessel 31 .
In the arrangement for monitoring of a metallurgical leaching process in a metallurgical leaching process vessel according to the present an- other embodiment the X-rays from said at least one X-ray tube 35 may be col- limated into a narrow beam in at least one dimension when propagating inside said metallurgical leaching process vessel 31 thus minimizing the amount of radiation to other directions than the detector. Furthermore, said at least one X-ray tube 35 may be arranged to move or turn in order to transmit X-ray radia- tion in multiple directions.
In the embodiment presented in Figure 6 at least one X-ray sensor unit 36 of said metallurgical leaching process vessel 31 detects an X-ray radiation transmitted by said opposing at least one X-ray tube unit 35, said X-ray radiation travelling inside said metallurgical leaching process vessel 31 .
From said detected X-ray radiation data a sensor data processing unit can provide a two-dimensional image related to the attenuation of X-rays the metallurgical process substance 34 inside said metallurgical leaching process vessel 31 based on the detected X-ray radiation data. Furthermore, said at least one X-ray sensor unit 36 may be arranged to move or turn in order to sense and provide a two- or three-dimensional image. Said at least one X-ray tube 35 and the at least one X-ray sensor unit 36 may be realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
Said image provided by said at least one X-ray sensor unit 36 gives information for the calculation, monitoring and controlling of process, e.g. metallurgical process substance 34 feed, dilution water feed and leaching reagent feed. Furthermore, said image provided by said at least one X-ray sensor unit 36 gives information for the calculation for the progress of the metallurgical leaching process and for the characteristics of the metallurgical process sub- stance 34 inside said metallurgical leaching process vessel 31 . Furthermore, the gas content and/or the liquid content, e.g. the water content of metallurgical slurry at different heights and the formation of solids in said metallurgical leaching process vessel 31 may be calculated based on said image provided by said at least one X-ray sensor unit 36. Online measurement will also give a long time average measurement result instead of an instantaneous indication.
The solution for monitoring of a metallurgical process in a metallurgical process vessel according to the present invention provides a continuous measurement of a metallurgical process substance in a metallurgical process vessel, which is highly insensitive to dirt or contamination. The solution for monitoring of a metallurgical process in a metallurgical process vessel accord- ing to the present invention provides reliable, online measurement data for the monitoring of the metallurgical process.
With the help of the solution according to the present invention the manufacturers and owners of metallurgical processes and metallurgical process vessels will be able to provide metallurgical process vessels with an ar- rangement producing more reliable measurement data for monitoring of a metallurgical process in a metallurgical process vessel. The solution according to the present invention may be utilised in any kind of a metallurgical process vessel within metallurgy.
It will be obvious to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims.

Claims

1. A method for monitoring of a metallurgical process in a metallurgical process vessel (7), (14), (26), (31), c h a r a c t e r i z e d by that the method comprises the steps of:
- transmitting X-ray radiation into the metallurgical process vessel
(7), (14), (26), (31) by at least one X-ray tube (18), (20), (22), (24), (29), (35);
- detecting X-ray radiation travelling inside said metallurgical process vessel (7), (14), (26), (31) by at least one X-ray sensor unit (19), (21), (23), (25), (30), (36); and
- providing a two- or three-dimensional image related to the attenuation of X-rays metallurgical process substance (15), (28), (34) inside said metallurgical process vessel (7), (14), (26), (31) based on the detected X-ray radiation data;
wherein at least one of said at least one X-ray tube (18), (20), (22), (24), (29), (35) and said at least one X-ray sensor unit (19), (21), (23), (25),
(30) , (36) is arranged inside said metallurgical process vessel (7), (14), (26),
(31) .
2. A method according to claim ^ characterized in that the method comprises the step of:
- controlling said metallurgical process based on the detected X-ray radiation data.
3. A method according to claim 1 or to claim 2, characterized in that the method comprises the step of:
- feeding the metallurgical process vessel (7), (14), (26), (31) with metallurgical process substance (15), (28), (34).
4. A method according to any one of claims 1 to 3, characterize d in that said metallurgical process vessel (7) is a thickener (7) or a clari- fier (7).
5. A method according to any one of claims 1 to 3, character- i z e d in that said metallurgical process vessel (14) is an electrolysis cell (14).
6. A method according to any one of claims 1 to 3, characterized in that said metallurgical process vessel (26), (31) is a leaching reactor (26), (31).
7. An arrangement for monitoring of a metallurgical process in a metallurgical process vessel (7), (14), (26), (31 ), c h a r a c t e r i z e d in that said arrangement comprises:
- at least one X-ray tube (18), (20), (22), (24), (29), (35), said at least one X-ray tube (18), (20), (22), (24), (29), (35) being arranged to transmit
X-ray radiation into said metallurgical process vessel (7), (14), (26), (31),
- at least one X-ray sensor unit (19), (21), (23), (25), (30), (36) arranged to detect X-ray radiation travelling inside said metallurgical process vessel (7), (14), (26), (31), and
- a sensor data processing unit, which said sensor data processing unit provides a two- or three dimensional image related to the attenuation of X- rays metallurgical process substance (15), (28), (34) inside said metallurgical process vessel (7), (14), (26), (31);
wherein at least one of said at least one X-ray tube (18), (20), (22), (24), (29), (35) and at least one X-ray sensor unit (19), (21), (23), (25), (30), (36) is arranged inside said metallurgical process vessel (7), (14), (26), (31).
8. An arrangement according to claim 7, characterized in that said arrangement comprises a sensor data processing unit, which said sensor data processing unit controls said metallurgical process based on the detected X-ray radiation data.
9. An arrangement according to claim 7 or to claim 8, characterized in that phase boundaries, distribution of solid content and/or density in the metallurgical process substance (15), (28), (34) inside said metallurgical process vessel (7), (14), (26), (31) is/are calculated based on the detected X-ray radiation data.
10. An arrangement according to any one of claims 7 to 9, c h a r - acterized in that the gas content and/or the liquid content of the metallurgical process substance (15), (28), (34) at different heights in said metallurgical process vessel (7), (14), (26), (31) is/are calculated based on the detected X- ray radiation data.
11. An arrangement according to any one of claims 7 to 10, characterized in that the distribution and/or content of anode slime (17) in said metallurgical process vessel (14) is calculated based on the detected X-ray radiation data.
12. An arrangement according to any one of claims 7 to 11, characterized in that the crud formation in said metallurgical process vessel (7), (14), (26), (31) is calculated based on the detected X-ray radiation data.
13. An arrangement according to any one of claims 7 to 12, characterized in that the X-rays from said at least one X-ray tube (18), (20), (22), (24), (29), (35) are collimated into a narrow beam in at least one dimension when propagating inside said metallurgical process vessel (7), (14), (26), (31).
14. An arrangement according to claim 13, characterized in that said at least one X-ray tube (18), (20), (22), (24), (29), (35) is arranged to move or turn in order to transmit X-ray radiation in multiple directions.
15. An arrangement according to any one of claims 7 to 14, characterized in that said at least one X-ray sensor unit (19), (21), (23), (25), (30), (36) is arranged to move or turn.
16. An arrangement according to any one of claims 7 to 15, characterized in that at least one of said at least one X-ray tube (18),
(20), (22), (24), (29), (35) and said at least one X-ray sensor unit (19), (21), (23), (25), (30), (36) is attached in a frame structure of said metallurgical process vessel (7), (14), (26), (31).
17. An arrangement according to any one of claims 7 to 16, characterized in that at least one of said at least one X-ray tube (18),
(20), (22), (24), (29), (35) and at least one X-ray sensor unit (19), (21), (23), (25), (30), (36) is attached outside a frame structure of said metallurgical process vessel (7), (14), (26), (31) and that said frame structure is manufactured of material, which does not absorb the X-rays and allows at least 1 %, prefera- bly at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through said frame structure of said metallurgical dewatering process vessel (7), (14), (26), (31).
18. An arrangement according to any one of claims 7 to 17, characterized in that at least one of said at least one X-ray tube (18), (20), (22), (24), (29), (35) and at least one X-ray sensor unit (19), (21), (23), (25), (30), (36) is attached outside a frame structure of said metallurgical process vessel (7), (14), (26), (31) and that the the frame structure of said metallurgical dewatering process vessel (7), (14), (26), (31) comprises one or more window portions, which said one or more window portions are manufactured of material, which does not absorb the X-rays and allows at least 1 %, preferably at least 5 %, more preferably at least 30 %, of the X-ray radiation to travel through the frame structure of said metallurgical dewatering process vessel (7), (14), (26), (31).
19. An arrangement according to any one of claims 7 to 18, characterized in that said at least one X-ray tube (18), (20), (22), (24), (29), (35) and said least one X-ray sensor unit (19), (21), (23), (25), (30), (36) are realized as at least one X-ray measurement unit or as at least one movable X-ray measurement unit.
20. An arrangement according to any one of claims 7 to 19, characterized in that said metallurgical process vessel (7) is a thicken- er (7) or a clarifier (7).
21. An arrangement according to any one of claims 7 to 19, characterized in that said metallurgical process vessel (14) is an electrolysis cell (14).
22. An arrangement according to any one of claims 7 to 19, characterized in that said metallurgical process vessel (26), (31 ) is a chemical reactor (26), (31) such as a leaching reactor (26), (31), a precipitation reactor, a reduction reactor or a synthesis reactor.
PCT/FI2016/050922 2015-12-23 2016-12-23 A method and an arrangement for monitoring of a metallurgical process in a metallurgical process vessel Ceased WO2017109296A1 (en)

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