Copper Produced Patents (Class 205/574)
  • Patent number: 10059586
    Abstract: In the thermochemical water splitting process by Cu—Cl cycle, oxygen gas is produced by a thermolysis process in a three-phase reactor. IN accordance with the teachings herein, a technique is provided to achieve the high challenging thermal requirements of the thermolysis reactor, whereby an optimized heat transfer configuration is used. The technique involves using some of the pre-heated stoichiometric oxygen gas produced from the thermolysis reaction, to transfer heat directly to the slurry of molten CuCl and solid Cu2OCl2 inside the thermolysis reactor. Experiments were performed to examine the volumetric heat transfer coefficient for the direct contact heat transfer between the gas and the slurry. It was found that the thermal scale up analysis of the thermolysis reactor with direct contact heat transfer, is based on the amount of heat carried by the oxygen gas rather than the amount of heat transferred by direct contact heat transfer.
    Type: Grant
    Filed: July 14, 2016
    Date of Patent: August 28, 2018
    Assignee: Mohammed Wassef Abdulrahman
    Inventor: Mohammed Wassef Abdulrahman
  • Patent number: 9938632
    Abstract: A method for recycling metallic material produced by an electrochemical material removal process. The method includes flowing an electrolyte solution between an anode workpiece and a cathode tool in a first electrolytic process, the first electrolytic process including applying a first electrolytic current and voltage between the anode workpiece and the cathode tool and thereby causing metal ions to be removed from the anode workpiece and dissolved and substantially retained in the electrolyte solution. The electrolyte solution with the metal ions therein is passed between an electrowinning cathode and an electrowinning anode in a second electrolytic process, the second electrolytic process including applying a second electrolytic current and voltage between the electrowinning cathode and the electrowinning anode and thereby causing the metal ions to be removed from the electrolyte solution and deposited onto the electrowinning cathode.
    Type: Grant
    Filed: September 4, 2015
    Date of Patent: April 10, 2018
    Assignee: FARADAY TECHNOLOGY, INC.
    Inventors: E. Jennings Taylor, Maria E. Inman, Brian T. Skinn, Timothy D. Hall, Stephen T. Snyder, Savidra C. Lucatero, Eric Lee Kathe
  • Patent number: 9023129
    Abstract: The invention is directed to a process and apparatus for recovering metals from bottom ash from incineration plants, such as municipal waste incineration plants. The process includes directing a feed containing ash into an oxidizing unit, wherein at least part of the metals is oxidized in the presence of one or more acids and at least one oxygen donor, thus producing a stream comprising metal ions. From this stream the metals of interest are selected and converted into metallic form.
    Type: Grant
    Filed: October 6, 2010
    Date of Patent: May 5, 2015
    Assignee: Elemetal Holding B.V.
    Inventors: Jeroen Pieter Netten, Silvan Johan Thus
  • Publication number: 20140353165
    Abstract: The electrolysis of cuprous chloride was carried out in the electrochemical cell. The particle size, current density, cathodic current efficiency, conversion of cuprous chloride and yield of copper formed depends strongly on current flow, heat transfer and mass transfer operation. The current flow, heat transfer and mass transfer are depends on surface area ratio of anode to cathode, distance between electrodes, concentration of HCl, applied voltage, flow rate of electrolyte, CuCl concentration and reaction temperature. The electrolysis of cuprous chloride as a part of Cu—Cl thermochemical cycle for hydrogen production is experimentally demonstrated in proof-of-concept work.
    Type: Application
    Filed: July 9, 2012
    Publication date: December 4, 2014
    Inventors: Yadav Ganapati Dadasaheb, Parhad Prakash Santoshrao, Nirukhe Ashwini Bhagavan, Parvatalu Damaraju, Bhardwaj Anil, Prabhu Bantwal Narayana, Thomas Nuzhath Joeman, Kale Dilip Madhusudan
  • Publication number: 20140318973
    Abstract: The present invention provides an electrolytic copper foil that has a high normal tensile strength, a low decrease in tensile strength after a thermal history, and a low concentration of impurities in the copper foil and a method for producing the copper foil. Specifically, the electrolytic copper foil in which a sulfur concentration of the copper foil is not less than 10 ppm by mass but no more than 50 ppm by mass, wherein when lattices with a spacing of 10 nm in a STEM image observed with a scanning transmission electron microscope at a magnification of 1 million times are formed and intersections of each lattice are used as a measurement point for determining a sulfur concentration, there is a measurement point at which the sulfur concentration is higher as compared to the sulfur concentration of the copper foil.
    Type: Application
    Filed: March 28, 2012
    Publication date: October 30, 2014
    Applicant: JX NIPPON MINING & METALS CORPORATION
    Inventor: Michiya Kohiki
  • Publication number: 20140286857
    Abstract: A method of preparing a metal containing inorganic ion exchanger in an electrochemical cell is disclosed. In one embodiment, the method comprises: (a) adding the inorganic ion exchanger to the electrochemical cell, wherein the electrochemical cell comprises a conductive electrolyte solution having a liquid phase and a solid phase; (b) depositing metal ions electrochemically into the liquid phase; (c) allowing the metal ions to deposit onto the inorganic ion exchanger during an electrochemical reaction to obtain a metal containing inorganic ion exchanger; (d) collecting the solid phase comprising the metal containing inorganic ion exchanger obtained in step (c); (e) removing remaining metal ions from the liquid phase; and (f) obtaining a substantially metal free liquid phase.
    Type: Application
    Filed: March 13, 2014
    Publication date: September 25, 2014
    Applicant: BASF CORPORATION
    Inventors: Ahmad Dehestani, Gerald Koermer, Mukta Rai
  • Publication number: 20140262810
    Abstract: The invention is directed to a method for producing metal-containing (e.g., non-oxide, oxide, or elemental) nano-objects, which may be nanoparticles or nanowires, the method comprising contacting an aqueous solution comprising a metal salt and water with an electrically powered electrode to form said metal-containing nano-objects dislodged from the electrode, wherein said electrode possesses a nanotextured surface that functions to confine the particle growth process to form said metal-containing nano-objects. The invention is also directed to the resulting metal-containing compositions as well as devices in which they are incorporated.
    Type: Application
    Filed: March 12, 2014
    Publication date: September 18, 2014
    Applicant: UT-Battelle, LLC
    Inventors: Adam Justin Rondinone, Ilia N. Ivanov, Sean Campbell Smith, Chengdu Liang, Dale K. Hensley, Ji-Won Moon, Tommy Joe Phelps
  • Publication number: 20140231269
    Abstract: The invention concerns a system of gas ducts (6) for transporting gas, for example, into electrolytic equipment, in connection with which there are means (13) for taking at least gas into the system of gas ducts, whereby there is a suitable number of gas supply holes (7) in the system of gas ducts in a wall (19) limiting the system of gas ducts, whereby the material, such as gas, flowing in the system of gas ducts (6) is prevented at least in part from passing through the wall (19) of the system of gas ducts (6). The invention also concerns equipment and a method for electrolytic recovery of metal, such as copper.
    Type: Application
    Filed: November 22, 2011
    Publication date: August 21, 2014
    Applicant: OUTOTEC OYJ
    Inventors: Ville Nieminen, Lauri Palmu, Henri Virtanen
  • Patent number: 8628725
    Abstract: A system for producing hydrogen gas from water decomposition using a thermochemical CuCl cycle, the improvement comprising the use of an insulated hydrogen production reactor comprising a reaction chamber and a separation chamber; the reaction chamber having a hydrogen chloride gas inlet and a solid copper inlet; one or more levels provided in the reaction chamber, the number of which is dependant on production scale and pressure drop; each level comprising a perforated plate with associated filter media, the perforations of the plate and media being of decreasing size from top to bottom of the reaction chamber, and being sized to permit downward flow of the hydrogen gas and molten CuCl products, as well as the HCL gas reactant, and to prevent entrainment of solid copper in the molten CuCl; the separation chamber being located below the reaction chamber and being of greater cross section than the reaction chamber and comprising a first hydrogen removal and entrained copper removal zone and a second molten CuC
    Type: Grant
    Filed: November 25, 2008
    Date of Patent: January 14, 2014
    Assignee: University of Ontario Institute of Technology
    Inventors: Kamiel Samy Gabriel, Zhaolin Wang, Greg Naterer
  • Patent number: 8617360
    Abstract: Methods and devices for the continuous manufacture of nanop?rticles, microparticles and nanoparticle/liquid solution(s) are disclosed. The nanoparticles (and/or micron-sized particles) comprise a variety of possible compositions, sizes and shapes. The particles (e.g., nanoparticles) are caused to be present (e. g., created) in a liquid (e.g., water) by utilizing at least one adjustable plasma (e.g., created by at least one AC and/or DC power source), which plasma communicates with at least a portion of a surface of the liquid. The continuous process causes at least one liquid to flow into, through and out of at least one trough member, such liquid being processed, conditioned and/or effected in said trough member(s).
    Type: Grant
    Filed: July 11, 2008
    Date of Patent: December 31, 2013
    Assignee: GR Intellectual Reserve, LLC
    Inventors: David K. Pierce, Mark G. Mortenson, David A. Bryce
  • Patent number: 8597477
    Abstract: The present invention relates to a contact bar assembly for use in a multi-cell electrolytic system for recovery of metal, to a system including the contact bar assembly, and to a method of using the assembly and system. The contact bar assembly includes a base cap board, a primary bar having a plurality of primary bar structures formed thereon, an auxiliary bar having a plurality of auxiliary bar structures formed thereon, and a top cap board, wherein the base cap board includes slots to receive the primary bar and the auxiliary bar, and wherein the top cap board includes a plurality of openings to receive the plurality of primary bar structures and the plurality of auxiliary bar structures. A system includes the contact bar assembly, an anode assembly, a cathode assembly, and a tank.
    Type: Grant
    Filed: February 16, 2011
    Date of Patent: December 3, 2013
    Assignee: Freeport-McMoran Corporation
    Inventors: Rafael Garcia Navarro, Luis A. Gonzalez Olguin, Luis Ricardo Olivares, Larry R. Todd, Mark Peabody, Casey J. Clayton, Scot P. Sandoval
  • Patent number: 8580089
    Abstract: A system is submitted here that permits superimposing an alternating current in the process of electrolytic refining of metals based on the use of power semiconductors without requiring an external source and which minimizes the utilization of passive elements, achieving a high efficiency solution applicable to high power industrial processes. The invention consists of the division of the cells involved in the metals electrolysis process in two groups of cells (3a) and 3b, both comprising a similar number of anode-cathode pairings, and with both groups linked by a common point for electrical connection (6), and interconnected by means of a bidirectional power converter (7). Said power converter (7) is connected to the common point for electrical connection 6 of the groups of cells (3a, 3b) and to the other two connection points of each group of cells, so that its operation permits transferring power from one group to the other.
    Type: Grant
    Filed: April 23, 2010
    Date of Patent: November 12, 2013
    Assignee: Ingenieria Y Desarrollo Technologico S.A.
    Inventors: Patricio Clemente Lagos Lehuede, Ricardo Armando Feuntes Fuentealba, Jorge Luis Estrada Gonzalez
  • Patent number: 8454809
    Abstract: A modular array of containers placed in parallel for electrolytic solutions used in metals electrolysis processes, particularly for metals electrowinning and electrorefining processes, assemblable from joinable and sealable prefabricated panels with other equal or similar ones, comprising at least a pair of opposite end walls (1, 2), lateral walls (3, 4), a plurality of floor panels (5) and a plurality of intermediate transverse walls (6), the modular array of containers having a common wall between two adjacent containers, the common wall defined by said intermediate transverse walls (6).
    Type: Grant
    Filed: October 28, 2009
    Date of Patent: June 4, 2013
    Assignee: Novel Composites Technologies S.A.
    Inventor: Miguel Maldonado Ramirez De Arellano
  • Patent number: 8361287
    Abstract: A multi-element cover system for controlling acid mist in metal electrowinning or electrorefining cells is made of an electrolyte resistant material and is applied above the surface of the electrolyte and below the electrical connections of the electrodes in order to provide a continuous and substantially airtight seal above the electrolyte.
    Type: Grant
    Filed: August 21, 2008
    Date of Patent: January 29, 2013
    Inventors: Fernando Penna Wittig, Cristian Villaseca Castro
  • Patent number: 8357271
    Abstract: The present invention aims to provide a zinc electrowinning anode capable of inhibiting manganese compound deposition on the anode and a cobalt electrowinning anode capable of inhibiting cobalt oxyhydroxide deposition on the anode. The zinc electrowinning anode according to the present invention is a zinc electrowinning anode having an amorphous iridium oxide-containing catalytic layer formed on a conductive substrate, and the zinc electrowinning method according to the present invention is an electrowinning method using that electrowinning anode. Also, the cobalt electrowinning anode according to the present invention is an electrowinning anode having an amorphous iridium oxide or ruthenium oxide-containing catalytic layer formed on a conductive substrate, and the cobalt electrowinning method according to the present invention is an electrowinning method using that electrowinning anode.
    Type: Grant
    Filed: June 9, 2009
    Date of Patent: January 22, 2013
    Assignee: The Doshisha
    Inventor: Masatsugu Morimitsu
  • Publication number: 20120298523
    Abstract: In a method for producing metal powder, the first part of an acid-containing starting solution is fed on the anode side of an electrolytic cell as anolyte, to contact the anode and supply material containing yield metal, and a second part of the acid-containing starting solution, which also contains intermediary metal, is fed on the cathode side of the electrolytic cell, to contact the cathode as catholyte. Yield metal is oxidized and dissolved in the anolyte by leading electric current in the anode. The yield metal contained in the second part of the starting solution is reduced on the cathode side. Anolyte solution and catholyte solution are fed to a precipitating chamber for mixing the dissolved, oxidized yield metal and the second part of the starting solution containing reduced intermediary metal.
    Type: Application
    Filed: January 25, 2011
    Publication date: November 29, 2012
    Applicant: OUTOTEC OYJ
    Inventors: Ville Nieminen, Henri Virtanen
  • Patent number: 8273237
    Abstract: The present invention relates, generally, to a method and apparatus for recovering metal values from a metal-bearing materials, and more specifically, a process for recovering copper and other metals through leaching, electrowinning using the ferrous/ferric anode reaction, and the synergistic addition of ferrous iron to the leach step.
    Type: Grant
    Filed: January 16, 2009
    Date of Patent: September 25, 2012
    Assignee: Freeport-McMoran Corporation
    Inventors: John O. Marsden, James D. Gillaspie, John C. Wilmot
  • Patent number: 8187450
    Abstract: The present invention relates, generally, to a method and apparatus for electrowinning metals, and more particularly to a method and apparatus for copper electrowinning using the ferrous/ferric anode reaction. In general, the use of a flow-through anode—coupled with an effective electrolyte circulation system—enables the efficient and cost-effective operation of a copper electrowinning system employing the ferrous/ferric anode reaction at a total cell voltage of less than about 1.5 V and at current densities of greater than about 26 Amps per square foot (about 280 A/m2), and reduces acid mist generation. Furthermore, the use of such a system permits the use of low ferrous iron concentrations and optimized electrolyte flow rates as compared to prior art systems while producing high quality, commercially saleable product (i.e., LME Grade A copper cathode or equivalent), which is advantageous.
    Type: Grant
    Filed: April 1, 2010
    Date of Patent: May 29, 2012
    Assignee: Freeport-McMoran Corporation
    Inventors: Scot Philip Sandoval, Timothy George Robinson, Paul Richard Cook
  • Patent number: 8133366
    Abstract: There is provided a substantially permanent stainless steel cathode plate suitable for use in electrorefining of metal cathodes, the cathode being composed of a low-nickel duplex steel or a lower grade “304” steel, wherein operational adherence of an electrodeposition thereon is enabled by altering various qualities of the cathode surface. There is also provided a method of producing the above duplex or Grade 304 cathode plates, such that the desired operational adherence of the deposit upon the plate is not so strong as to prevent the deposit being removed during subsequent handling.
    Type: Grant
    Filed: August 24, 2010
    Date of Patent: March 13, 2012
    Assignee: Xstrata Queensland Limited
    Inventor: Wayne Keith Webb
  • Patent number: 8097132
    Abstract: A metal-containing material is introduced in the container with an anode inserted therein, the container is introduced in a tank filled with an electrolyte, with a cathode opposed to it, and direct current is passed through ((+) anode and (?) cathode) to recover the desired metal.
    Type: Grant
    Filed: June 28, 2007
    Date of Patent: January 17, 2012
    Inventor: Luis Antonio Canales Miranda
  • Patent number: 7993501
    Abstract: In various embodiments, the present invention provides an electrolytic cell contact bar having a first pole and a pair of second poles. The second poles are opposite in charge to the first pole and each of the pair of second poles are adjacent to and parallel to the first pole. In various embodiments, the contact bar may include an electrode holder capable of holding at least one electrode.
    Type: Grant
    Filed: November 6, 2008
    Date of Patent: August 9, 2011
    Assignee: Freeport-McMoran Corporation
    Inventors: Bret Ashford, William A Ebert, Fernando D Mollo Vega, Samuel Rasmussen, Timothy G Robinson, Scot P Sandoval
  • Publication number: 20110123389
    Abstract: High purity copper having a purity of 6N or higher, wherein content of each of the respective components of P, S, 0, and C is 1 ppm or less, and nonmetal inclusions having a particle size of 0.5 ?m or more and 20 ?m or less contained in the copper are 10,000 inclusions/g or less. As a result of using high purity copper or high purity copper alloy as the raw material from which harmful P, S, C, 0-based inclusions have been reduced and controlling the existence form of nonmetal inclusions, it is possible to reduce the occurrence of rupture of a bonding wire and improve the reproducibility of mechanical properties, or reduce the percent defect of a semiconductor device wiring formed by sputtering a high purity copper target with favorable reproducibility.
    Type: Application
    Filed: September 24, 2009
    Publication date: May 26, 2011
    Applicant: JX NIPPON MINING & METALS CORPORATION
    Inventors: Yuichiro Shindo, Susumu Shimamoto, Atsushi Fukushima
  • Publication number: 20110056842
    Abstract: In a process for the operation of copper electrolysis cells including a plurality of anode and cathode plates arranged vertically and parallel to each other, a longitudinal electrolyte inflow and an electrolyte outflow, the electrolyte is injected via the electrolyte inflow horizontally and parallel to the electrodes in each electrode gap always at the height of the lower third of the electrodes at a speed of from 0.3 to 1.0 m/s, with the cathode plates being arranged stationarily relative to the inflow direction. As a result, an optimized flow guidance of the electrolyte with regard to the electrodes is achieved, resulting in an increase in the limiting current density.
    Type: Application
    Filed: August 7, 2008
    Publication date: March 10, 2011
    Applicant: METTOP GMBH
    Inventors: Andreas Filzwieser, Iris Filwieser
  • Publication number: 20100276297
    Abstract: Electrowinning methods and apparatus are suitable for producing elemental deposits of high quality, purity, and volume. Respective cathodes are used during electrowinning for bearing the elemental product, segregating impurities, dissolving morphologically undesirable material, and augmenting productivity. Silicon suitable for use in photovoltaic devices may be electrodeposited in solid form from silicon dioxide dissolved in a molten salt.
    Type: Application
    Filed: April 21, 2010
    Publication date: November 4, 2010
    Applicant: METAL OXYGEN SEPARATION TECHNOLOGIES, INC.
    Inventors: Adam C. Powell, IV, Steve J. Derezinski, III
  • Patent number: 7794580
    Abstract: A method of winning a metal from its oxide ore by heating the ore in a partial vacuum or under an inert atmosphere in the presence of a reductant. The resulting product may be further reduced electrochemically to produce a purer metal.
    Type: Grant
    Filed: December 6, 2005
    Date of Patent: September 14, 2010
    Assignee: Materials & Electrochemical Research Corp.
    Inventors: James C. Withers, Raouf O. Loutfy
  • Publication number: 20100187125
    Abstract: The present invention relates, generally, to a method and apparatus for electrowinning metals, and more particularly to a method and apparatus for copper electrowinning using the ferrous/ferric anode reaction. In general, the use of a flow-through anode—coupled with an effective electrolyte circulation system—enables the efficient and cost-effective operation of a copper electrowinning system employing the ferrous/ferric anode reaction at a total cell voltage of less than about 1.5 V and at current densities of greater than about 26 Amps per square foot (about 280 A/m2), and reduces acid mist generation. Furthermore, the use of such a system permits the use of low ferrous iron concentrations and optimized electrolyte flow rates as compared to prior art systems while producing high quality, commercially saleable product (i.e., LME Grade A copper cathode or equivalent), which is advantageous.
    Type: Application
    Filed: April 1, 2010
    Publication date: July 29, 2010
    Applicant: FREEPORT-MCMORAN CORPORATION
    Inventors: Scot Philip Sandoval, Timothy George Robinson, Paul Richard Cook
  • Publication number: 20100163425
    Abstract: Ultrahigh purity copper having a residual resistance ratio of 38,000 or greater and a purity of 8N or higher (excluding gas components of O, C, N, H, Sand P), and in particular ultrahigh purity copper wherein the respective elements of O, C, N, H, S and P as gas components are 1 ppm or less is provided.
    Type: Application
    Filed: March 11, 2010
    Publication date: July 1, 2010
    Applicant: NIPPON MINING & METALS CO., LTD.
    Inventors: Yuichiro Shindo, Kouichi Takemoto
  • Patent number: 7736488
    Abstract: The present invention relates generally to a process for recovering copper and/or other metal values from a metal-bearing ore, concentrate, or other metal-bearing material using pressure leaching and direct electrowinning. More particularly, the present invention relates to a substantially acid-autogenous process for recovering copper from chalcopyrite-containing ore using pressure leaching and direct electrowinning in combination with a leaching, solvent/solution extraction and electrowinning operation.
    Type: Grant
    Filed: December 29, 2008
    Date of Patent: June 15, 2010
    Assignee: Freeport-McMoran Corporation
    Inventors: John O Marsden, Robert E Brewer, Susan R Brewer, Joanna M Robertson, David R Baughman, Philip Thompson, Wayne W Hazen, Christel M. A. Bemelmans
  • Patent number: 7736486
    Abstract: This invention relates to a system and method for producing a metal powder product using conventional electrowinning chemistry (i.e., oxygen evolution at an anode) in a flow-through electrowinning cell. The present invention enables the production of high quality metal powders, including copper powder, from metal-containing solutions using conventional electrowinning processes and/or direct electrowinning.
    Type: Grant
    Filed: May 23, 2008
    Date of Patent: June 15, 2010
    Assignee: Freeport-McMoran Corporation
    Inventors: Antonioni C Stevens, Stanley R Gilbert, Scot P Sandoval, Timothy G Robinson, John O Marsden
  • Patent number: 7722756
    Abstract: A system and process for recovering copper from a copper-containing ore, concentrate, or other copper-bearing material to produce high quality cathode copper from a leach solution without the use of copper solvent/solution extraction techniques or apparatus. A process for recovering copper from a copper-containing ore generally includes the steps of providing a feed stream containing comminuted copper-containing ore, concentrate, or other copper-bearing material, leaching the feed stream to yield a copper-containing solution, conditioning the copper-containing solution through one or more physical or chemical conditioning steps, and electrowinning copper directly from the copper-containing solution in multiple electrowinning stages, without subjecting the copper-containing solution to solvent/solution extraction prior to electrowinning.
    Type: Grant
    Filed: November 19, 2008
    Date of Patent: May 25, 2010
    Assignee: Freeport-McMoran Corporation
    Inventors: John O Marsden, Joanna M Robertson, Robert E Brewer, Susan R. Brewer, legal representative, David R Baughman, Philip Thompson, Wayne W Hazen, Christel M. A. Bemelmans
  • Publication number: 20100089763
    Abstract: Contemplated configurations and methods allow for effective removal of copper from aqueous media by selectively concentrating copper in a first stage, wherein competing metal ions are subjected to a redox reaction to thereby increase selective concentration. Copper is then plated in a flow through electrode from a relatively concentrated copper solution that is depleted from competing non-copper metals. In preferred aspects, the first stage provides a copper-depleted effluent that includes zinc and/or manganese for further recovery.
    Type: Application
    Filed: September 26, 2007
    Publication date: April 15, 2010
    Inventors: Brackenbury Darron, Chulheung Bae, Brian J. Dougherty, Stephen Harrison
  • Patent number: 7601247
    Abstract: A cell (100) for metal electrowinning from metal ion solutions is described, wherein the cathode (1) consists of a falling bed of growing beads; the beads, withdrawn from the lower part of the bed, are recycled to the top section of the cathodic compartment by means of an external vertical duct (3).
    Type: Grant
    Filed: June 23, 2004
    Date of Patent: October 13, 2009
    Assignee: De Nora Elettrodi S.p.A.
    Inventors: Douglas J. Robinson, Stacey A. MacDonald, Davide Scotti, Francesco Todaro
  • Patent number: 7591934
    Abstract: This invention relates to an apparatus for producing a metal powder product using either conventional electrowinning or alternative anode reaction chemistries in a flow-through electrowinning cell. A new design for a flow-through electrowinning cell that employs both flow-through anodes and flow-through cathodes is described. The present invention enables the production of high quality metal powders, including copper powder, from metal-containing solutions using conventional electrowinning processes, direct electrowinning, or alternative anode reaction chemistry.
    Type: Grant
    Filed: June 30, 2008
    Date of Patent: September 22, 2009
    Assignee: Freeport-McMoran Corporation
    Inventors: John O Marsden, Scot P Sandoval, Antonioni C Stevens, Timothy G Robinson, Stanley R Gilbert
  • Patent number: 7550068
    Abstract: A system, device, and method include a cell-powered first electronic device powered using electrical potential imposed across an electrolytic cell. The potential is voltage-boosted to accomplish this task. If the electrical potential imposed the cell is insufficient, the device can also be battery-powered. In any event, this device is in communication with one or more sensors in the electrolytic cell, as well as a second electronic device, and the first and second electronic devices wirelessly communicate. More specifically, the first electronic device wireless transmits data signals to the second electronic device, which receives the same. The first and second electronic devices are physically remote from one another, and they communicating over a private or public network, preferably using spread spectrum technology.
    Type: Grant
    Filed: March 17, 2005
    Date of Patent: June 23, 2009
    Assignee: Kennecott Utah Copper Corporation
    Inventors: Eugene Yanjun You, Antonio Berges-Dreyfous, David B. George, Roger Roth, Keming Zhou, Minyan Ruan
  • Publication number: 20090152124
    Abstract: In various embodiments, the present invention provides an electrolytic cell contact bar having a first pole and a pair of second poles. The second poles are opposite in charge to the first pole and each of the pair of second poles are adjacent to and parallel to the first pole. In various embodiments, the contact bar may include an electrode holder capable of holding at least one electrode.
    Type: Application
    Filed: November 6, 2008
    Publication date: June 18, 2009
    Applicant: PHELPS DODGE CORPORATION
    Inventors: Brett Ashford, William A. Ebert, Fernando D. Mollo Vega, Samuel Rasmussen, Timothy G. Robinson, Scot P. Sandoval
  • Patent number: 7494580
    Abstract: The present invention relates, generally, to a method for electrowinning copper powder, and more particularly to a method for electrowinning copper powder from a copper-containing solution using the ferrous/ferric anode reaction. In accordance with various embodiments of the present invention, a process for producing copper powder by electrowinning employs alternative anode reaction technology, namely, the ferrous/ferric anode reaction, and enables the efficient and cost-effective production of copper powder at a total cell voltage of less than about 1.5 V and at current densities of greater than 50 A/ft2. A copper powder electrowinning process in accordance with the present invention also reduces or eliminates acid mist generation that is characteristic of electrowinning operations utilizing conventional electrowinning chemistry (e.g., oxygen evolution at the anode), which is advantageous.
    Type: Grant
    Filed: July 14, 2005
    Date of Patent: February 24, 2009
    Assignee: Phelps Dodge Corporation
    Inventors: Scot P Sandoval, Antonioni C Stevens, Timothy G Robinson, John O Marsden, Stanley R Gilbert
  • Patent number: 7494579
    Abstract: It is herein described an electrowinning cell with a spouted bed electrode of growing metallic beads, separated by a semi-permeable diaphragm and suitable for being assembled in a stack in a modular arrangement.
    Type: Grant
    Filed: July 11, 2003
    Date of Patent: February 24, 2009
    Assignee: De Nora Elettrodi S.p.A.
    Inventors: Douglas J. Robinson, Stacey A. MacDonald, Vladimir Jiricny, Dario Oldani, Francesco Todaro, Leonello Carrettin, Gian Nicola Martelli, Davide Scotti
  • Patent number: 7485216
    Abstract: The present invention relates generally to a process for recovering copper and/or other metal values from a metal-bearing ore, concentrate, or other metal-bearing material using pressure leaching and direct electrowinning. More particularly, the present invention relates to a substantially acid-autogenous process for recovering copper from chalcopyrite-containing ore using pressure leaching and direct electrowinning in combination with a leaching, solvent/solution extraction and electrowinning operation.
    Type: Grant
    Filed: October 28, 2005
    Date of Patent: February 3, 2009
    Assignee: Phelps Dodge Corporation
    Inventors: John O. Marsden, Susan R. Brewer, legal representative, Joanna M. Robertson, David R. Baughman, Philip Thompson, Wayne W. Hazen, Christel M. A. Bemelmans, Robert E. Brewer
  • Patent number: 7476308
    Abstract: A system and process for recovering copper from a copper-containing ore, concentrate, or other copper-bearing material to produce high quality cathode copper from a leach solution without the use of copper solvent/solution extraction techniques or apparatus. A process for recovering copper from a copper-containing ore generally includes the steps of providing a feed stream containing comminuted copper-containing ore, concentrate, or other copper-bearing material, leaching the feed stream to yield a copper-containing solution, conditioning the copper-containing solution through one or more physical or chemical conditioning steps, and electrowinning copper directly from the copper-containing solution in multiple electrowinning stages, without subjecting the copper-containing solution to solvent/solution extraction prior to electrowinning.
    Type: Grant
    Filed: October 29, 2004
    Date of Patent: January 13, 2009
    Assignee: Phelps Dodge Corporation
    Inventors: John O. Marsden, Robert E. Brewer, Joanna M. Robertson, David R. Baughman, Phillip Thompson, Wayne W. Hazen, Christel M. A. Bemelmans
  • Patent number: 7470351
    Abstract: A system for producing metal particles using a discrete particle electrolyzer cathode, a discrete particle electrolyzer cathode, and methods for manufacturing the cathode. The cathode has a plurality of active zones on a surface thereof at least partially immersed in a reaction solution. The active zones are spaced from one another by between about 0.1 mm and about 10 mm, and each has a surface area no less than about 0.02 square mm. The cathode is spaced from an anode also at least partially immersed in the reaction solution. A voltage potential is applied between the anode and cathode. Metal particles form on the active zones of the cathode. The particles may be dislodged from the cathode after they have achieved a desired size. The geometry and composition of the active zones are specified to promote the growth of high quality particles suitable for use in metal/air fuel cells. Cathodes may be formed from bundled wire, machined metal, chemical etching, or chemical vapor deposition techniques.
    Type: Grant
    Filed: April 24, 2003
    Date of Patent: December 30, 2008
    Assignee: Teck Cominco Metals Ltd.
    Inventors: Stuart I. Smedley, Martin De Tezanos Pinto, Stephen R. Des Jardins, Donald James Novkov, Ronald Gulino
  • Patent number: 7470356
    Abstract: A system, device, and method include a cell-powered first electronic device for monitoring two or more electrolytic cells is powered using electrical potential imposed across the electrolytic cells. The potential is voltage-boosted to accomplish this task. If the electrical potential imposed across the cells is insufficient, the device can also be battery-powered. In any event, this device is in communication with one or more sensors in the electrolytic cells, as well as a second electronic device, and the first and second electronic devices wirelessly communicate. More specifically, the first electronic device wireless transmits data signals to the second electronic device, which receives the same. The first and second electronic devices are physically remote from one another, and they communicate over a private or public network, preferably using spread spectrum technology.
    Type: Grant
    Filed: June 8, 2006
    Date of Patent: December 30, 2008
    Assignee: Kennecott Utah Copper Corporation
    Inventors: Eugene Yanjun You, Daniel Kang Kim
  • Patent number: 7462272
    Abstract: A system and process for recovering copper from a copper-containing ore, concentrate, or other copper-bearing material to produce high quality cathode copper from a leach solution without the use of copper solvent/solution extraction techniques or apparatus. A process for recovering copper from a copper-containing ore generally includes the steps of providing a feed stream containing comminuted copper-containing ore, concentrate, or other copper-bearing material, leaching the feed stream to yield a copper-containing solution, conditioning the copper-containing solution through one or more physical or chemical conditioning steps, and electrowinning copper directly from the copper-containing solution in multiple electrowinning stages, without subjecting the copper-containing solution to solvent/solution extraction prior to electrowinning.
    Type: Grant
    Filed: October 28, 2005
    Date of Patent: December 9, 2008
    Assignee: Phelps Dodge Corporation
    Inventors: John O. Marsden, Susan R. Brewer, legal representative, Joanna M. Robertson, David R. Baughman, Philip Thompson, Wayne W. Hazen, Christel M. A. Bemelmans, Robert E. Brewer
  • Patent number: 7452455
    Abstract: This invention relates to a system and method for producing a metal powder product using either conventional electrowinning or alternative anode reaction chemistries in a flow-through electrowinning cell. The present invention enables the production of high quality metal powders, including copper powder, from metal-containing solutions using conventional electrowinning processes, direct electrowinning, or alternative anode reaction chemistries.
    Type: Grant
    Filed: July 14, 2005
    Date of Patent: November 18, 2008
    Assignee: Phelps Dodge Corporation
    Inventors: Scot P Sandoval, Antonioni C Stevens, Timothy G Robinson, John O Marsden, Stanley R Gilbert
  • Patent number: 7445696
    Abstract: For an electrolytic cell, an apparatus and method are described that use one or more sensors to measure magnetic field strength about a conductor carrying electrical current. A processor is in electrical communication with the sensors and determines a compensated magnetic field strength based on the magnetic fields of other conductors that also carry electrical current to or from the electrolytic cell. The processor uses this compensated magnetic field strength to determine the cathode electrical current carried by the conductor and to identify open and short circuits between the anodes and cathodes of the cell. The described apparatus and method account for interactions between the magnetic fields of the neighboring cathodes.
    Type: Grant
    Filed: March 17, 2005
    Date of Patent: November 4, 2008
    Assignee: Kennecott Utah Copper Corporation
    Inventors: Eugene Yanjun You, Antonio Berges-Dreyfous, David B. George, Daniel Kim, Keming Zhou
  • Publication number: 20080229882
    Abstract: The present invention relates to a process for purifying sulphuric acids, in particular metal-containing sulphuric acids, characterized in that monodisperse ion exchangers having chelating functional groups are used.
    Type: Application
    Filed: August 23, 2004
    Publication date: September 25, 2008
    Inventors: Olaf Halle, Wolfgang Podszun, Bruno Hees, Rheinhold Klipper, Jean-Marc Vesselle
  • Publication number: 20080223728
    Abstract: Ultrahigh purity copper having a residual resistance ratio of 38,000 or greater and a purity of 8N or higher (excluding gas components of O, C, N, H, S and P), and in particular ultrahigh purity copper wherein the respective elements of O, C, N, H, S and P as gas components are 1 ppm or less.
    Type: Application
    Filed: January 5, 2005
    Publication date: September 18, 2008
    Applicant: NIPPON MINING & METALS CO., LTD.
    Inventors: Yuichiro Shindo, Kouichi Takemoto
  • Publication number: 20080217185
    Abstract: This invention relates to a system and method for producing a metal powder product using conventional electrowinning chemistry (i.e., oxygen evolution at an anode) in a flow-through electrowinning cell. The present invention enables the production of high quality metal powders, including copper powder, from metal-containing solutions using conventional electrowinning processes and/or direct electrowinning.
    Type: Application
    Filed: May 23, 2008
    Publication date: September 11, 2008
    Applicant: PHELPS DODGE CORPORATION
    Inventors: Antonioni C. Stevens, Stanley R. Gilbert, Scot P. Sandoval, Timothy G. Robinson, John O. Marsden
  • Publication number: 20080142374
    Abstract: An apparatus for recovering a metal, which comprises a metal-recovering board (2) having an electrodeposition surface (2a, 2t) for the attachment of a metal component (R) precipitated from a solution and an insulating material (2b) formed around a pattern of the electrodeposition surface (2a, 2t). The metal-recovering board (2) is immersed in a metal-containing solution in an electrolytic treatment vessel (1), and thereby the metal in the solution is selectively precipitated on the electrodeposition surface (2a, 2t) and is converted to a bulk. The resultant metal bulk is scraped together for recovery with a blade (6) in a form as it is. The above apparatus for recovering a metal can be suitably used for recovering a metal in a solution in a state allowing easy reuse with good efficiency.
    Type: Application
    Filed: August 12, 2005
    Publication date: June 19, 2008
    Applicant: THE FURUKAWA ELECTRIC CO., LTD.
    Inventors: Hisashi Iwama, Hiroaki Tanaka, Harunobu Kimura, Hitoshi Tanaka, Yutaka Hirota
  • Patent number: 7384533
    Abstract: Electrolytic solutions containing organic additive(s) selected from a described class of additives (e.g., 4,6-dihydroxypyrimidine) reduce overall applied electrical potential of electrolytic cells and/or reduce gas formation at the anode(s) or increase copper production rate. Benefits include reducing overall power consumption and reducing acid mist during electrolytic processes.
    Type: Grant
    Filed: July 10, 2002
    Date of Patent: June 10, 2008
    Assignee: 3M Innovative Properties Company
    Inventors: Michael J. Sierakowski, L. Charles Hardy, Michael S. Terrazas, Jennifer E. Waddell, Bryan J. Johnson
  • Patent number: 7378010
    Abstract: This invention relates to a system and method for producing a metal powder product using conventional electrowinning chemistry (i.e., oxygen evolution at an anode) in a flow-through electrowinning cell. The present invention enables the production of high quality metal powders, including copper powder, from metal-containing solutions using conventional electrowinning processes and/or direct electrowinning.
    Type: Grant
    Filed: July 14, 2005
    Date of Patent: May 27, 2008
    Assignee: Phelps Dodge Corporation
    Inventors: Antonioni C Stevens, Stanley R Gilbert, Scot P Sandoval, Timothy G Robinson, John O Marsden