Fluid treatment apparatus and process

Abstract

Liquid treatment apparatus comprises at least two chambers being first and second chambers through which a fluid can flow. The two chambers are separated by at least one choke nozzle which has an entrance in the first chamber and an exit in the second chamber. The choke nozzle comprises a converging section at its entrance, a throat section, a backward-facing step immediately after the throat section, and an exit section at its exit wherein the exit section diverges from the step. Similarly constructed mixing nozzles may be included in the apparatus. The apparatus is especially useful in processes requiring a gas to be entrained in a fluid so that the gas is in the form of very small bubbles that do not tend to coalesce and flash off such as in the dissolution of gold and other precious metals from ore and in the removal of arsenic from an ore.

Claims

1. Fluid treatment apparatus for conducting a physical or chemical reaction in which a slurry and a gas are contacted such that the slurry and at least a component of the gas partake in the physical or chemical reaction, the fluid treatment apparatus comprising at least two chambers being first and second chambers through which a fluid can flow, the two chambers being separated by at least one choke nozzle which has an entrance in the first chamber and an exit in the second chamber, wherein the choke nozzle comprises a converging section at its entrance, a throat section, a backward-facing step immediately after the throat section, and an exit section at its exit which opens into the second chamber wherein the choke nozzle is configured to promote cavitation resulting from choked flow wherein the apparatus includes one or more gas inlets having their axes extending transversely at an offset in a generally tangential direction relative to slurry flow so that a swirling action of diffusing gas in the slurry results, the apparatus being characterized in that mixing nozzles are included in the apparatus for mixing fluids either before they enter a choke nozzle or after they leave a choke nozzle, or both and wherein a mixing nozzle has a converging section at its entrance, a throat section, a backward-facing step immediately after the throat section, and an exit section at its exit which opens into a downstream chamber.

2. Fluid treatment apparatus as claimed in claim 1 in which the choke nozzle's converging section, the throat and the exit section are each of circular shape in cross-section and the exit section diverges.

3. Fluid treatment apparatus as claimed in claim 1 in which the converging section of a nozzle has a cone angle of from 1 to 35 degrees.

4. Fluid treatment apparatus as claimed in claim 3 in which the cone angle is from 15 to 30 degrees.

5. Fluid treatment apparatus as claimed in claim 1 in which the backward-facing step of a choke nozzle extends radially outwards beyond the throat section by 3 to 10% of the diameter of the throat.

6. Fluid treatment apparatus as claimed in claim 5 in which the backward-facing step extends radially outwards beyond the throat section by from 4 to 8%.

7. Fluid treatment apparatus as claimed in claim 1 in which the exit section diverges with a cone angle of from 1 to 8 degrees.

8. Fluid treatment apparatus as claimed in claim 7 in which the exit section diverges with a cone angle of from 2 to 8 degrees.

9. Fluid treatment apparatus as claimed in claim 1 in which a diverging exit section to a nozzle has additional successive backward-facing steps along the exit section.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a sectional elevation of a choke nozzle which can be used in many different embodiments of the invention;

(2) FIG. 2 is a similar sectional elevation of a mixing nozzle having multiple axially spaced backward-facing steps downstream of the throat section which can be used in many different embodiments of the invention;

(3) FIG. 3 is an elevation of one embodiment of an apparatus according to the invention that is particularly aimed at enhancing gas diffusion within a fluid and showing two choke nozzles and two coaxial mixing nozzles in dotted lines;

(4) FIG. 4 is a cross-sectional view of the apparatus shown in FIG. 1 taken along line II to II;

(5) FIG. 5 is a schematic sectional elevation of an alternative embodiment of an apparatus according to the invention using additional arrangements of nozzles;

(6) FIG. 6 is a schematic sectional plan view taken along line VI to VI of the embodiment of apparatus according to the invention shown in FIG. 5;

(7) FIG. 7 is a schematic sectional elevation of an alternative embodiment of an apparatus according to the invention using a single axial mixing nozzle as its inlet;

(8) FIG. 8 is a schematic sectional elevation of an alternative and simplified embodiment of apparatus according to the invention;

(9) FIG. 9 is a schematic diagram of the progression of a cavitation bubble imploding close to a fixed surface generating a jet of the surrounding liquid;

(10) FIG. 10 is a schematic diagram showing how sonoluminescence develops in the direction from left to right;

(11) FIG. 11 shows a low velocity jet that exhibits intermittent gas entrainment;

(12) FIG. 12 shows a high velocity jet that exhibits how gas entrapment can occur through turbulence within a jet of fluid exiting a choke nozzle and through the shear layer surrounding the jet exiting the choke nozzle;

(13) FIG. 13 illustrates how gas entrapment can occur through splashing of fluid out of a receiving cup of a nozzle;

(14) FIG. 14 shows a diagram of flow through a de Laval nozzle, showing approximate flow velocity (v), together with the effect on temperature (T) and pressure (P);

(15) FIG. 15 illustrates gas entrapment by a droplet entering a stationary pool of liquid;

(16) FIG. 16 is a block diagram of a possible two-stage process for using apparatus of the present invention in association with a single tank;

(17) FIG. 17 is a graph showing results of a practical test for demonstrating the efficacy of the invention as applied to the leaching of gold;

(18) FIG. 18 is a graph showing the reduction in cyanide consumption in the test on which FIG. 17 is based; and,

(19) FIG. 19 is a graph showing results of a practical test for demonstrating the efficacy of the invention as applied to the dissolution of arsenic from a process solution.

DETAILED DESCRIPTION OF THE INVENTION

(20) In the process of the invention in which a gas is to be dispersed in a fluid, the gas is injected into the fluid such that ultra-fine bubbles are formed, preferably below 1 micrometre in diameter and even more preferably in the picometre diameter range, such that the tiny bubbles behave like solid spheres in the liquid and do not coalesce or flash off. The creation of ultra-fine bubbles increases the gas hold-up in the fluid; increases the mass transfer of gas into fluid; accelerates chemical reactions; and facilitates the flotation of ultra-fine particles.

(21) Although the invention is described herein in detail for the recovery of gold from ore and for the dissolution of oxygen into a slurry or pulp of milled ore, water and cyanide, it will be apparent to a person skilled in the art that the invention could have many other applications. These include the pre-oxidation of mineral pulps; accelerated leaching of various metal values in the minerals industry, e.g. gold, platinum group metals and base metals such as copper, cobalt, nickel, zinc, manganese and lead, as well as uranium; for partial or total sulphide oxidation of various minerals, e.g. in the treatment of refractory gold ore; for the destruction of cyanide and for arsenic remediation in the gold industry; for the treatment of acid mine drainage; for water treatment applications; for applications in the paper and pulp industry; for applications in the biodiesel industry; for conditioning and ultra-fine bubble generation in the flotation industry; and for gas scrubbing.

(22) As mentioned above, one of the problems with existing methods for injecting gas into a liquid or suspension is the low linear velocities (under 10 m/s) inherent to these systems, which limits the shear and mixing and hence also the bubble size.

(23) A predicted bubble size (diameter) for a fluid velocity of 10 m/s has been calculated to be between 80 and 100 micrometres (microns). Even if it were possible to increase fluid velocities to 25 m/s, bubble size would still only be around 50 micrometres.

(24) The process of the present invention, on the other hand, results in the formation of bubbles which are smaller than 50 micrometres, preferably in the nanometre or even picometre range. This can be achieved by initially generating bubbles in the 50 micrometre size range through shear, and subsequently imploding the bubbles down to nanometre or picometre range by harnessing the energy of cavitation.

(25) Inertial cavitation is a process where a void or bubble in a liquid rapidly collapses, producing a shock wave (FIG. 9). Since the shock waves formed by cavitation are strong enough to significantly damage moving parts, cavitation is usually an undesirable phenomenon. However, in the present invention, conditions favorable for cavitation are deliberately created and the energy released during cavitation is harnessed and utilized to create nanometre or picometre size bubbles (“nano-bubbles” or “pico-bubbles”), to dissolve gases and to promote chemical reactions that would otherwise not occur or would occur very slowly (as free radicals are generated in the process due to disassociation of vapours trapped in the cavitating bubbles).

(26) Hydrodynamic cavitation describes the process of vaporization, bubble generation and bubble implosion which occurs in a flowing liquid as a result of a decrease and subsequent increase in pressure. Cavitation will only occur if the pressure declines to a point below the saturated vapour pressure of the liquid. In pipe systems, cavitation typically occurs either as the result of an increase in the kinetic energy (through an area constriction) or an increase in the pipe elevation.

(27) Hydrodynamic cavitation can be produced by passing a liquid through a constricted channel at a specific velocity or by mechanical rotation through a liquid. In the present invention, a constricted channel and the specific geometry of the system create a combination of pressure and kinetic energy enabling a hydrodynamic cavitation cavern downstream of the local constriction to generate high energy cavitation bubbles.

(28) The process of bubble generation, subsequent growth and collapse of the cavitation bubbles results in very high energy densities, resulting in very high temperatures and pressures at the surface of the bubbles for a very short time. The overall liquid medium environment, therefore, remains at ambient conditions.

(29) The invention may be implemented using a wide variety of different choke nozzles and mixing nozzles in which gas bubbles are formed in a fluid by accelerating the fluid through the choke nozzle one variety of which is shown in FIG. 1. The choke nozzle (1) has a fluid inlet (2), a convergent entry cone (3), a throat section (4) where the cross-sectional area of the choke nozzle is a minimum at the narrow end of the convergent entry cone, a backward facing step (5) immediately downstream of the throat section, and a somewhat divergent exit cone or diffuser section (6) with a fluid outlet (7). The entry cone is angled at from about 10 to about 40 degrees, more particularly from about 15 to about 35 degrees, and even more particularly from about 25 to about 35 degrees, and most particularly at about 30 degrees.

(30) The diameter of the throat section may be selected so as to choke the flow of fluid so that the velocity of any bubbles in the fluid becomes sonic in the throat section. The backward facing step (5) can have a step height of about 1 to about 4 mm, and more particularly of about 2 to about 4 mm in the instance of smaller diameter throats which h falls within the range of about 4.5-5% of the throat diameter. The diffuser section (6) has an angled wall with an included angle of from about 1 to about 9 degrees, more particularly of from about 2 to 8 degrees, and even more particularly of from about 4 to 8 degrees with a particular preference being about 4 degrees. The choke nozzle surface can be rough or pitted. The choke nozzle can be lined with a wear resistant material, such as fused or reaction bonded SiSiC, alumina, HDPE, polyurethane or rubber, a liner being indicated by numeral (8).

(31) In use entrained gas is accelerated past the backward facing step (5), which creates high speed eddies and turbulence within the jet of fluid, resulting in ventilated void bubble formation with subsequent implosion. Bubble implosion is further assisted by the diverging angle of the diffuser section (6) which increases the local (static) pressure in the choke nozzle as the nozzle diameter increases. Depending on the gas, it may change phase and liquefy at the point of highest compression.

(32) FIG. 2 of the drawings of the other hand illustrates a mixing nozzle that is very much elongated and the entry cone (11) of each mixing nozzle is as described above. The entry cone connects to a very much longer throat section (12), the length of which is equivalent to from about 3 to about 15, and more particularly from about 7 to about 15, diameters of the throat section. Immediately downstream of the throat section is a first backward facing step (13) with a step height in the range of about 2 to about 25 mm, and more particularly about 4 to about 25 mm. There can be a number of subsequent backward facing steps, in this instance two, additional backward facing steps (14, 15), axially spaced at distances equivalent to about 1 to about 10, and more particularly about 3 to about 10, diameters of the preceding backward facing step. The backward facing steps create a diffuser section with an included angle typically of from about 2 to about 30 degrees, and more particularly of from about 4 to about 30 degrees. The fluid velocity in the throat of the mixing nozzle may be between 3 and 12 m/s, most preferably between 8 and 10 m/s. The mixing nozzle may have a lining and be encased as described above.

(33) In each instance, air or other gases, or even liquids, can be injected into the fluid at various points such as at the point of fluid discharge from the nozzle (assisted by the slight vacuum created by the fluid flow), where it further ventilates the voids and is broken down into small bubbles by the implosion of the voids in the highly turbulent region downstream of the nozzle. The break-up of the fluid greatly increases the contact area between the fluid and the gas to further enhance dissolution of oxygen in the fluid. The gas injection may be tangential and will then result in a swirling action of the fluid, so aiding mixing and generating centrifugal acceleration. Reagents may also be injected into the fluid at this point to ensure maximum mixing and reaction.

(34) By accelerating the fluid through a choke nozzle described above, the angular velocity of the fluid can be around 240 000 rpm and the centrifugal acceleration can be around 60 000 g (g being the acceleration due gravity) at a point close to the centre of the exit of the choke nozzle (around 1 mm from the centre). This, coupled with the straight line acceleration (10 000 g) through the choke nozzle, creates extreme cavitation conditions within the choke nozzle with ventilated void bubbles spreading from the outer circumference (owing to the straight line acceleration) to the inner core (owing to the centrifugal acceleration).

(35) Thus, nanometre and even picometre size bubbles can be generated by creating a vacuum bubble by accelerating the fluid to drop the instantaneous pressure to below the vapour pressure of the fluid, so creating a void bubble; ventilating the void bubble with a gas; and imploding the void bubble by increasing the instantaneous pressure to above the vapour pressure of the fluid to form a multitude of tiny bubbles of an enhanced size.

(36) This acceleration is achieved by one or more of straight line acceleration through the choke nozzle from about 0.4 m/s to about 25 m/s to generate about 10 000 g (g being the acceleration due to gravity); centrifugal acceleration with angular velocities around 240 000 rpm to generate around 60 000 g at a point near the centre of the choke nozzle (around 1 mm from the centre); centrifugal acceleration of around 60 000 g as a result of eddy formation created by the backward facing steps in the choke nozzle; and, acceleration due to gravity by height difference (geodetic height).

(37) The acceleration has the effect of “tearing” holes in the liquid to form voids which are ventilated and imploded. The void can seed on hydrophobic particles in the fluid, on existing microscopic voids already in the fluid, or on surface irregularities of the solid surfaces that provide “leading edges” for cavitation.

(38) The overall effect of the fluid moving through the choke nozzle is that of an ultrahigh speed swirling jet with ultrahigh speed eddies that cavitate from both its straight line as well as its centrifugal acceleration.

(39) The turbulence within the fluid jet is also an important factor for facilitating gas entrainment as the free jet from one nozzle plunges into the receiving cup or entry cone section of a nozzle below.

(40) Referring to FIG. 12, the speed of the gas is subsonic as it is drawn into the choke nozzle, but it becomes sonic as it is compressed and passes through the point of narrowest diameter. As it passes into the region of the backward facing step where the diameter abruptly increases, the gas will expand and accelerate to supersonic speeds, generating a shock wave (sound wave) within the jet of fluid. This sound wave would have the effect of causing further cavitation in the jet and, in an extreme case, even breaking up the fluid into a coarse spray to greatly increase surface area for maximum contact with the surrounding gas. As gas is entrained and carried away by the fluid flow, more gas is drawn into the fluid creating a suction effect.

(41) Although a pressurized gas would not necessarily be required for gas entrainment to take place, it would be preferred owing to the higher resultant gas velocities in the fluid and the possibility of generating supersonic gas flows through the nozzles.

(42) Sonoluminescence may occur in the process of the present invention, owing to the shockwaves generated by the gas reaching supersonic speeds and the inertial cavitation in the diffuser sections of the nozzles. FIG. 10 shows the progression from left to right about the upper echelon of a bubble followed by slow expansion and thereafter quick and sudden contraction followed by the emission of light.

(43) Reverting now to the practical implementation of the invention, FIGS. 3 and 4 show one arrangement in which a series of axially spaced nozzles (21, 22, 23, 24) are mounted coaxially in tubular apparatus (25). The first nozzle is a mixing nozzle (21) followed by two successive axially spaced choke nozzles (22, 23) with a final mixing nozzle (24). In this instance there are four tangential gas inlets (26) in the throat of the first mixing nozzle (21) and additional gas inlets (27) that are also tangentially arranged at the outlet (28) from the mixing nozzle (21).

(44) The two choke nozzles (22, 23) each have four tangentially arranged inlets (29) to feed air or other fluid into of the throat (30) of each choke nozzle. FIG. 4 shows clearly the tangential nature of the gas inlets.

(45) FIGS. 5 and 6 illustrate another arrangement of nozzles according to the invention in a more complex apparatus. In this arrangement the apparatus has a Tee type of inlet pipe (31) leading into a first chamber (32). The inlet pipe may have one or more points for pressure measurement and gas and/or liquid injection (not shown). The first chamber (32) is typically a vertical cylindrical pipe with a length of from about 0.3 m to about 1 m, more particularly from about 0.4 m to about 1 m, and even more particularly from about 0.6 m to about 1 m. The first chamber (32) and inlet pipe (31) can be manufactured from HDPE, steel lined with rubber, polyurethane or any other suitable material.

(46) A roof section (33) of the first chamber (32) can be flanged to allow for removal for maintenance purposes. At least one choke nozzle, and in this instance two choke nozzles (34) of the type shown in FIG. 1 are located in a floor (35) of the chamber, leading to a second chamber (36) which is similar to the first chamber. A similar arrangement of choke nozzles (37) is positioned in the floor of the second chamber with its axis on the centre line of the upstream choke nozzles (34) and are spaced apart so that the distance between the exit of an upstream nozzle and the upper portion of the downstream nozzle is equivalent to from about 1 to 3, and more particularly about 2 to 3 diameters of the upstream nozzle exit.

(47) Additional chambers with choke nozzles or mixing nozzles may be similarly arranged in a succession below those described above with the nozzles being positioned one below the other. In the wall of each chamber, in line with or slightly below the exit point of each nozzle, there is typically at least one inlet for the addition of one or more gases or liquids to the chamber preferably in a direction that results in swirling.

(48) A further chamber (41) with a height of from about 0.4 m to about 1 m, and more particularly from about 0.6 m to about 1 m receives the fluid from the last of a succession of nozzles. This further chamber (41) is closed at its base but has a pair of opposite tangential outlets (42) located in the side wall. Those tangential outlets (42) lead to yet a further in line chamber (44), via a conduit (45) laterally offset from the first and second chambers, and a return tangential inlet (46) that may have a choke nozzle (47), which is of the same type described above. The choke nozzle (47) is typically positioned within the return inlet (46) as close as possible to the in line chamber (44). There may be a plurality of choke nozzles arranged in parallel depending on the flow rate to be accommodated.

(49) In the wall of inlet (46), at or about a point where the exit of the nozzle (47) is positioned, there is typically at least one inlet (48) for the addition of one or more gases or liquids. The height of in line chamber (44) can be from about 0.4 m to about 1 m, and more particularly from about 0.8 m to about 1 m. The in line chamber (44) has a closed roof and has choke nozzles (51) of the type described above in its floor, leading to yet a further chamber. A succession of chambers (52) may follow as described above with gas inlets (53) provided, as may be required, at the outlets of the choke nozzles. The final set of nozzles may be mixing nozzles of the elongated variety described above with reference to FIG. 2. They may be positioned from about 2 to about 10, and more particularly from about 3 to about 10, nozzle exit diameters away from the exits from the upstream choke nozzles.

(50) The mixing nozzles discharge into a relatively large chamber (54) compared to the previous chambers from which an exit conduit (55) extends. The length of the exit conduit is typically from about 0.4 m to about 1 m, and more particularly from about 0.5 m to about 1 m. The exit conduit may feed tangentially or in Tee fashion into an outlet chamber (56) that has a bottom discharge outlet (57).

(51) Rubber bellows or elephant hose (not shown) may be installed at any interface between pipework feeding fluid to the apparatus of the invention and discharging the fluid away from the apparatus. The rubber bellows would absorb unwanted vibration and so assist with protecting the integrity of welds or joins and the sturdiness of the apparatus.

(52) In use, a fluid of milled ore, water and calcium cyanide or sodium cyanide may be fed into the first chamber (32) through the inlet pipe (31). The velocity of the fluid at its entry into the chamber should be in the range of from about 1.5 m/s to about 25 m/s, and more particularly in the range of about 2.5 m/s to about 25 m/s. At a point just before the entry point the back-pressure of the fluid should be about 3 to about 10 bar, and more particularly about 5 to about 10 bar. Gases or other liquids can be injected into the fluid at or near this point through entry points described above. The gases or liquids should be pressurized to pressures of from about 5 to about 20 bar, and more particularly from about 10 to about 20 bar, and can be injected either directly into the fluid or via a nozzle arrangement.

(53) The gases or liquids introduced downstream should also be pressurized to pressures of from about 5 to about 20 bar, and more particularly from about 10 to about 20 bar, and can be injected either directly into the fluid or via a nozzle arrangement, or could alternatively be self-aspirated owing to the vacuum created by the fluid flowing through the nozzle.

(54) Gas entrapment can occur within or between the nozzles via one or more of the following mechanisms through turbulence within the jet exiting a nozzle (FIG. 12); through the shear layer surrounding the jet exiting the nozzle (FIG. 12); through the recirculating eddies between the jet exiting the nozzle and the liquid/suspension in the receiving pool of the nozzle located below it; between the wall of the receiving cup of the nozzle located below the jet and the liquid/suspension in the cup of the receiving nozzle; by splashing of liquid/suspension out of the receiving pool (FIG. 13).

(55) Other embodiments of the invention are depicted in FIGS. 7 and 8. FIG. 7 shows a simplified embodiment of the invention, incorporating only a plurality of choke nozzles as illustrated in FIG. 5 for a more compact design. FIG. 7 also shows a coaxial inlet (61) in which there is installed a mixing nozzle (62). An inlet chamber (63) communicates directly with an arrangement of tangential outlets (64) and tangential inlet (65) with reference to FIG. 5. The choke nozzles are indicated by numeral (66).

(56) FIG. 8 shows a more simplified arrangement in which there are simply three layers of choke nozzles (67) between a Tee inlet (68) and a Tee outlet (69).

(57) The process and apparatus of the present invention can be arranged to result in an increased rate of cyanide destruction compared to known processes.

(58) The commercially accepted process for cyanide destruction utilises a combination of SO.sub.2 and air with a CuSO.sub.4 catalyst in a well-agitated tank to oxidise cyanide to cyanate and so “destroy” the cyanide. One of the shortcomings of this process is the high reagent consumption. Some minerals also compete for the SO.sub.2, resulting in unsuccessful destruction of the cyanide to the accepted industry standard of 50 ppm.

(59) The reactor of the present invention can be used in the following two-stage process in the first of which the pH and Eh adjustment is carried out utilizing the reactor (with air or oxygen injection into the reactor) in addition to an Eh modifier such as SO.sub.2/air and a catalyst such as copper sulphate. Other Eh modifiers such as peroxide, manganese dioxide, sodium hypochlorite, potassium permanganate, potassium dichromate or ozone may also be utilized. In a second stage oxidation of cyanide by carbon catalysis utilizing activated carbon such as that used in a carbon in leach plant is carried out.

(60) In its simplest form, the two stage mechanism described above can be performed simultaneously in a single tank, with appropriate screening technology utilized to prevent the carbon from entering the reactor. Pumping of carbon through the reactor would result in undesirable increased carbon abrasion and breakage, with loss of potentially gold bearing carbon to tailings.

(61) When the SO.sub.2/air with copper sulphate catalyst, together with carbon catalyzed cyanide destruction, are used in the above process, it represents a hybrid between the known INCO process (as described in U.S. Pat. No. 4,537,686) and the Maelgwyn process (US Publication Number 2010/0307977). This hybrid process uses significantly less reagents than required for the INCO process (as little as one tenth of the INCO reagents). The hybrid process also employs the catalytic effect of activated carbon to ensure the destruction of cyanide via two different mechanisms (SO.sub.2/air and activated carbon catalysis). The process is able to reduce the residence time required in the Maelgwyn process, with a positive Eh value for successful destruction, and also results in the simultaneous leaching and recovery of precious metals such as gold, by adsorption onto the carbon.

(62) More importantly, the hybrid process as described above can be performed in a single stage, as opposed to the multiple stages required for the Maelgwyn Process.

(63) FIG. 16 shows a flow diagram of how the reactor of the present invention can be integrated into a carbon in leach plant. A reactor (71) according to the invention can be installed in the first two tanks (72) to reduce reagent consumption and accelerate leach kinetics. This could free up the last two tanks to be utilized for cyanide destruction and arsenic and heavy metal removal. In addition to catalyzing the leach reaction, the carbon in the last tank would also ensure that soluble gold losses are kept to a minimum.

(64) A test was conducted using a standard SO.sub.2/air cyanide destruction process as described in U.S. Pat. No. 4,537,686 in a single 60 minute stage with standard reagent addition (2:1 stoichiometric ratio of SO.sub.2 to cyanide) (Table 1), and this was compared to the hybrid process of the present invention as described above for the same time period (Table 2). From similar weak acid dissociable cyanide starting values, the process of the present invention resulted in lower final cyanide values than the SO.sub.2/air process and utilized only one tenth of the reagents used in the SO.sub.2/air process.

(65) TABLE-US-00001 TABLE 1 Cyanide destruction using a commercial SO.sub.2/Air process SO2/Air Reagent/CN Stage 1 Free CN ppm 94 WAD CN ppm 96 Thiocyanate ppm 5.8 Total CN ppm 97 Test Slurry Flow Rate mL/min 16 Conditions Solid Flow Rate g/min 10.1 Stage Residence min 60 Time 4-5 Hours pH 9.25 Eh mV 136 SMBS g/t 992 CuSO4•5H2O g/t 258 Lime g/t 488 Free CN ppm 0.03 WAD CN ppm 0.07 Thiocyanate ppm 4.7 Total CN ppm 0.64

(66) TABLE-US-00002 TABLE 2 Cyanide destruction using the process of the present invention. Gold Ore Hybrid Detox Data Stage 2 Free CN ppm 26 WAD CN ppm 98 Thiocyanate ppm 4.2 Total CN ppm 41 Test Slurry Flow Rate mL/min 9.1 Conditions Solid Flow Rate g/min 5.49 Stage Residence min 30 Time 6-7.5 Hours pH 8.68 Eh mV 101 SMBS g/t 118 CuSO4•5H2O g/t 226.8 H.sub.2SO.sub.4 g/t 44 Free CN ppm 0.04 WAD CN ppm 0.03 Thiocyanate ppm 1.2 Total CN ppm 0.08

(67) These tests were repeated under the same conditions but using a feed material of different mineralogy (Tables 3 and 4). The commercial SO.sub.2/air process was unable to render a final cyanide value of below 50 ppm, which is an industry regulated standard for effluent discharge.

(68) TABLE-US-00003 TABLE 3 Cyanide destruction using a commercial SO.sub.2/air process SO2/Air Reagent/CN Stage 1 WAD CN ppm 163 Total CN ppm 173 Test Slurry Flow Rate mL/min 16 Conditions Solid Flow Rate g/min 10.1 Stage Residence min 60 Time 4-5 Hours pH 9.25 Eh mV 136 SMBS g/t 1580 CuSO4•5H2O g/t 60 Lime g/t 530 WAD CN ppm 77 Total CN ppm 87

(69) TABLE-US-00004 TABLE 4 Cyanide destruction using the process of the present invention Gold Ore Hybrid Detox Reagent/CN Stage 2 WAD CN ppm 164 Total CN ppm 173 Test Slurry Flow Rate mL/min 16 Conditions Solid Flow Rate g/min 10.1 Stage Residence min 30 Time 4-5 Hours pH 8.52 Eh mV 88 SMBS g/t 250 CuSO4•5H2O g/t 60 H.sub.2SO.sub.4 g/t 51 WAD CN ppm 12 Total CN ppm 17

(70) The process of the present invention thus not only has the potential to be significantly more cost effective and environmentally friendly than existing technologies, but is also potentially technically superior.

(71) Subsequently an industrial scale plant trial was carried out over a period of 20 days of the first 10 days being run with the reactor of this invention is switched off and the second 10 days being run with the reactor switched on. The gold residue results are shown in FIG. 17 and the cyanide consumption results are shown in FIG. 18. There is a distinct improvement of a reduction in the residual gold in the residue of naught 0.32 g/t and an improvement in the cyanide consumption of 84 g/t which was a reduction of 36%.

(72) The foregoing relates mostly to the introduction of gas such as an oxidizing gas into a fluid. However, there are other applications of the invention in which the introduction of gas is not necessary, and one of these is in the destruction of arsenic removal.

(73) Arsenic occurs naturally in underground rock in a stable form which doesn't dissolve in water. However, when the rock is mined and the ore is brought to the surface and into contact with air, the arsenic is converted to an unstable form which readily dissolves in water. Thus, wastewater from mining operations frequently contains high concentrations of arsenic. As arsenic is toxic to both humans and animals, steps need to be taken to reduce the risks of contamination of groundwater from the wastewater, and the internationally acceptable upper limit for arsenic in wastewater from mining operations is presently set at 0.1 ppm. Mining operations which produce wastewater with higher levels of arsenic generally need to line their tailings dams with a layer of plastic to prevent any possible contamination of the environment. This is not only very expensive, but also does not prevent or reduce the creation of toxic waste.

(74) A reactor of the present invention can be used to leach the arsenic out of the native mined mineral ore and into solution within a relatively short period of a few hours. The dissolved arsenic can then be precipitated out of the solution as scorodite, a stable form of arsenic which does not dissolve in water and is therefore not toxic, or a scorodite-like mineral.

(75) The arsenic remediation can be carried out as an initial step prior to metal extraction utilising a mechanically agitated tank with a reactor on recirculation with air or oxygen addition into the reactor (ozone may also be used). In order to effect the leaching of the arsenic, the following reagents may be employed sodium metabisulphite (SMBS) or caustic soda (NaOH); and hydrochloric acid (HCl) or sulphuric acid (H.sub.2SO.sub.4);

(76) Ferric chloride can be used to effect the precipitation of arsenic as stable scorodite or scorodite-like minerals.

(77) Two tests were conducted on gold ore containing reactive Gersdorffite and nickeline, both of which are unstable forms of arsenic.

(78) The first test was conducted under the following standard gold leaching conditions to serve as a control or base case: 24 hour leach time; 5 kg/t NaCN addition; 10 g/l carbon addition; 40% solids; test conducted in agitated vat.

(79) The second test utilized the same leach conditions as the first, but with a prior arsenic leaching and precipitation stage conducted under the following conditions: 800 g/t SMBS; 300 g/t copper sulphate; 2 kg/t HCl; 50 g/t phosphoric acid; 50 g/t alum; 300 g/t ferric chloride; 4 hour residence time; 40% solids; 10 reactor passes with oxygen addition (one pass equals one vessel volume turnover); test conducted in agitated vat.

(80) The results of these tests are shown in Table 5. JR691 is the control/base test and JR689 is the test incorporating the arsenic leaching and precipitation according to the invention.

(81) TABLE-US-00005 TABLE 5 Arsenic and residual gold values after gold leaching Au Au Au Au Au Au As Au ppm ppm ppm ppm ppm ppm mg/l ppm rpt1 rpt2 rpt3 rpt4 rpt5 Average soln JR689 0.65 0.59 0.58 0.58 0.60 0.62 0.60 <0.10 24 hrs RESI JR691 0.95 0.98 0.97 1.00 0.94 1.03 0.98 1.30 24 hrs RESI

(82) The process incorporating the arsenic leaching and precipitation step resulted in arsenic in solution values below detection at less than 0.1 ppm arsenic at the end of the leach. The control/base test, however, showed 1.30 ppm arsenic at the end of the leach. This is significant, as the arsenic values of the control/base test do not comply with environmental regulations whereas the process incorporating the arsenic leaching and precipitation step of this invention is environmentally compliant.

(83) In addition, the process incorporating the arsenic leaching and precipitation step had a gold residue 0.38 g/t lower than the base/control test, which provides a significant economic benefit and a valuable boost to gold production levels.

(84) Thus, the reactor of the present invention can be used to leach out and precipitate arsenic from minerals, so rendering the arsenic more stable and resulting in little or no further leaching of arsenic when deposited on tailings storage facilities. This results in compliance with regulations relating to arsenic levels in groundwater and discharge into natural waterways. The process can also provide higher levels of gold recovery.

(85) The results of an industrial scale test are shown in FIG. 19 for four different conditions namely an untreated condition and four different conditions involving a process according to the invention equating to 3 reactor passes for a duration of 4 hours with different additions of ferric chloride and sodium metabisulphite (SMBS), as reflected in FIG. 19. The additions were 2.5 kg/t ferric chloride and 240 g/t SMBS; 1.75 kg/t ferric chloride and 2.23 kg/t SMBS; 1.00 kg/t ferric chloride and 3.5 kg/t SMBS; and 0.00 kg/t ferric chloride and 5.5 kg/t SMBS.

(86) Numerous other processes can doubtless be carried out using the apparatus and process of this invention.