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Constant Underflow Leaching 6pages

Leaching is a process used to extract soluble constituents from solid mixtures, crucial in hydrometallurgy and various industries. The constant underflow condition simplifies the design of multi-stage leaching systems by maintaining a fixed liquid-to-solid ratio, enhancing recovery efficiency. This method is widely applicable in industries such as metal extraction, food processing, and pharmaceuticals, demonstrating significant solute recovery potential.

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Shaik Assad
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294 views6 pages

Constant Underflow Leaching 6pages

Leaching is a process used to extract soluble constituents from solid mixtures, crucial in hydrometallurgy and various industries. The constant underflow condition simplifies the design of multi-stage leaching systems by maintaining a fixed liquid-to-solid ratio, enhancing recovery efficiency. This method is widely applicable in industries such as metal extraction, food processing, and pharmaceuticals, demonstrating significant solute recovery potential.

Uploaded by

Shaik Assad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

1.

Introduction to Leaching

Leaching is a separation process where soluble constituents are removed from a solid mixture
using a suitable solvent. It is widely applied in hydrometallurgy for extracting metals such as copper,
uranium, and gold, as well as in food and pharmaceutical industries for recovering oils, sugars, and
bioactive compounds. Efficiency of leaching depends on the solid-to-liquid ratio, choice of solvent,
mixing, temperature, and whether the operation is batch or continuous.
2. Concept of Constant Underflow Condition

In multi-stage leaching equipment such as thickeners, there are two exit streams: - Overflow:
containing clear solution rich in solute. - Underflow: containing solids and associated solution. The
constant underflow condition assumes that underflow leaves with a fixed ratio of liquid to solid
regardless of solute concentration. For example, if underflow ratio is 1 kg liquid per kg solid, every
stage discharges slurry in this proportion. This simplifies design and analysis of multi-stage
systems.
3. Material Balance with Constant Underflow

Key parameters: - F = solid feed rate (kg/h) - Sf = solute in feed (kg/h) - L = solvent flow rate (kg/h) -
R = liquid-to-solid ratio in underflow (kg liquid/kg solid) - n = number of stages Underflow from each
stage = F + RF. Overall balance: Solute in feed + Solute in solvent = Solute in overflow + Solute in
underflow. This balance allows calculation of solute recovery and solvent requirements.
4. Multistage Counter-Current Leaching

Counter-current operation means fresh solids enter stage 1 while fresh solvent enters the last
stage. They move in opposite directions, allowing maximum solute recovery. The constant
underflow assumption ensures that every stage’s slurry has a predictable solid–liquid ratio. This
improves recovery efficiency because solution leaving one stage becomes the input for the next,
progressively enriching solvent with solute while solids get leaner.
5. Industrial Applications and Example

Industries: - Hydrometallurgy: copper, uranium, and gold extraction. - Food processing: sugar
recovery, oil extraction. - Pharmaceuticals: extraction of plant-based compounds. Example:
Consider 1000 kg/h solid feed with 200 kg solute. Underflow ratio = 1.0, solvent = 1500 kg/h. Using
3 stages, calculations show over 85% solute recovery is achievable, demonstrating the efficiency of
multi-stage constant underflow systems.
6. Conclusion

The constant underflow condition in leaching is a simplifying assumption used to design and
analyze continuous counter-current processes. It ensures predictable slurry composition, easier
material balance calculations, and reliable recovery predictions. Though actual operations may vary
slightly, this model remains a cornerstone in hydrometallurgical and chemical engineering design
due to its practicality and effectiveness.

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