US 5,670,033 A · Process for making copper metal powder, copper oxides and copper foil

Abstract

This invention is directed to a process for making copper metal powder from copper-bearing material, comprising: (A) contacting said copper-bearing material with an effective mount of at least one aqueous leaching solution to dissolve copper ions in said leaching solution and form a copper-rich aqueous leaching solution; (B) contacting said copper-rich aqueous leaching solution with an effective amount of at least one water-insoluble extractant to transfer copper ions from said copper-rich aqueous leaching solution to said extractant to form a copper-rich extractant and a copper-depleted aqueous leaching solution; (C) separating said copper-rich extractant from said copper-depleted aqueous leaching solution; (D) contacting said copper-rich extractant with an effective amount of at least one aqueous stripping solution to transfer copper ions from said extractant to said stripping solution to form a copper-rich stripping solution and a copper-depleted extractant; (E) separating said copper-rich stripping solution from said copper-depleted extractant to form a first electrolyte solution; (F) advancing said first electrolyte solution to an electrolytic cell equipped with at least one first anode and at least one first cathode, and applying an effective amount of voltage across said first anode and said first cathode to deposit copper metal powder on said first cathode; and (G) removing copper metal powder from said first cathode. In one embodiment the first electrolyte solution used in step (F) is characterized by a chloride ion concentration of up to about 5 ppm. In one embodiment the first electrolyte solution used in step (F) contains at least one triazole. In one embodiment the copper metal powder is convened to copper foil. In one embodiment the copper metal powder is converted to cuprous oxide, cupric oxide or a mixture thereof; these copper oxides can be readily dissolved in sulfuric acid and used to make copper foil.

Claims31

Dependent claims

A process for making copper metal powder from a copper-bearing material, comprising:

(A) contacting said copper-bearing material with an effective amount of at least one aqueous leaching solution to dissolve copper ions in said leaching solution and form a copper-rich aqueous leaching solution;
(B) contacting said copper-rich aqueous leaching solution with an effective mount of at least one water-insoluble extractant to transfer copper ions from said copper-rich aqueous leaching solution to said extractant to form a copper-rich extractant and a copper-depleted aqueous leaching solution;
(C) separating said copper-rich extractant from said copper-depleted aqueous leaching solution;
(D) contacting said copper-rich extractant with an effective mount of at least one aqueous stripping solution to transfer copper ions from said extractant to said stripping solution to form a copper-rich stripping solution and a copper-depleted extractant;
(E) separating said copper-rich stripping solution from said copper-depleted extractant to form a first electrolyte solution;
(F) advancing said first electrolyte solution into an electrolytic cell equipped with at least one first anode and at least one first cathode, said electrolyte solution being characterized by a free chloride concentration of up to about 5 ppm, and applying an effective mount of voltage across said first anode and said first cathode to deposit copper metal powder on said first cathode;
and
(G) removing copper metal powder from said first cathode.

5 more elements

A process for making copper metal powder from a copper-bearing material, comprising:

(A) contacting said copper-bearing material with an effective amount of at least one aqueous leaching solution to dissolve copper ions in said leaching solution and form a copper-rich aqueous leaching solution;
(B) contacting said copper-rich aqueous leaching solution with an effective amount of at least one water-insoluble extractant to transfer copper ions from said copper-rich aqueous leaching solution to said extractant to form a copper-rich extractant and a copper-depleted aqueous leaching solution;
(C) separating said copper-rich extractant from said copper-depleted aqueous leaching solution;
(D) contacting said copper-rich extractant with an effective amount of at least one aqueous stripping solution to transfer copper ions from said extractant to said stripping solution to form a copper-rich stripping solution and a copper-depleted extractant;
(E) separating said copper-rich stripping solution from said copper-depleted extractant to form a first electrolyte solution;
(F) advancing said first electrolyte solution into an electrolytic cell equipped with at least one first anode and at least one first cathode, said electrolyte solution being characterized by a free chloride concentration of up to about 5 ppm, and applying an effective amount of voltage across said first anode and said first cathode to deposit copper metal powder on said first cathode;
(G) removing copper metal powder from said first cathode;
(H) dissolving said copper powder from step (G) in an aqueous sulfuric acid solution to form a second electrolyte solution;
(I) flowing said second electrolyte solution in an electroforming cell between a second anode and a second cathode, said second cathode being a rotating cathode, and applying an effective amount of voltage across said second anode and said second cathode to deposit copper foil on said second cathode;
and
(J) removing said copper foil from said second cathode.

8 more elements

A process for making copper metal powder from a copper-bearing material, comprising:

(A) contacting said copper-bearing material with an effective amount of at least one aqueous leaching solution to dissolve copper ions in said leaching solution and form a copper-rich aqueous leaching solution;
(B) contacting said copper-rich aqueous leaching solution with an effective amount of at least one water-insoluble extractant to transfer copper ions from said copper-rich aqueous leaching solution to said extractant to form a copper-rich extractant and a copper-depleted aqueous leaching solution;
(C) separating said copper-rich extractant from said copper-depleted aqueous leaching solution;
(D) contacting said copper-rich extractant with an effective amount of at least one aqueous stripping solution to transfer copper ions from said extractant to said stripping solution to form a copper-rich stripping solution and a copper-depleted extractant;
(E) separating said copper-rich stripping solution from said copper-depleted extractant to form a first electrolyte solution;
(F) advancing said first electrolyte solution into an electrolytic cell equipped with at least one first anode and at least one first cathode, said electrolyte solution being characterized by a free chloride concentration of up to about 5 ppm, and applying an effective amount of voltage across said first anode and said first cathode to deposit copper metal powder on said first cathode;
(G) removing copper metal powder from said first cathode;
(H') calcining said copper metal powder from step (G) to form cupric oxide, cuprous oxide, or a mixture thereof;
(H) dissolving said cupric oxide, cuprous oxide or mixture thereof from step (H') in an aqueous sulfuric acid solution to form a second electrolyte solution;
(I) flowing said second electrolyte solution in an electroforming cell between a second anode and a second cathode, said second cathode being a rotating cathode, and applying an effective amount of voltage across said second anode and said second cathode to deposit copper foil on said second cathode;
and
(J) removing copper foil from said second cathode.

9 more elements

A process for making copper metal powder from a copper-bearing material, said process including sequential steps (A), (B-1), (C-1), (B-2), (C-2), (E), (F) and (G), said process comprising:

(A) contacting said copper-bearing material with an effective amount of at least one aqueous leaching solution to dissolve copper ions in said leaching solution and form a copper-rich aqueous leaching solution;
(B-1) contacting said copper-rich aqueous leaching solution with an effective amount of at least one copper-bearing water-insoluble extractant from step (C-2) to transfer copper ions from said copper-rich aqueous leaching solution to said copper-bearing extractant to form a copper-rich extractant and a first copper-depleted aqueous leaching solution;
(C-1) separating said copper-rich extractant from said first copper-depleted aqueous leaching solution, advancing said copper-rich extractant to step (D);
(B-2) contacting said first copper-depleted aqueous leaching solution from step (C-1) with an effective amount of at least one copper-depleted extractant from step (E) to transfer copper ions from said first copper-depleted aqueous leaching solution to said copper-depleted extractant to form a copper-bearing extractant and a second copper-depleted aqueous leaching solution;
(C-2) separating said copper-bearing extractant from said second copper-depleted aqueous leaching solution, recirculating said copper-bearing extractant to step (B-1);
(D) contacting said copper-rich extractant from step (C-1) with an effective mount of at least one aqueous stripping solution to transfer copper ions from said copper-rich extractant to said stripping solution to form a first electrolyte solution and a copper-depleted extractant;
(E) separating said first electrolyte solution from said copper-depleted extractant, recirculating said copper-depleted extractant to step (B-2);
(F) advancing said first electrolyte solution to an electrolytic cell equipped with at least one first anode and at least one first cathode, said first electrolyte solution being characterized by a free chloride concentration of up to about 5 ppm, and applying an effective mount of voltage across said first anode and said first cathode to deposit copper powder on said first cathode;
and
(G) removing copper metal powder from said first cathode.

7 more elements

A process for making copper foil from a copper-bearing material, said process including sequential steps (A), (B-1), (C-1), (B-2), (C-2), (D), (E), (F), (G), (H), (I) and (J), said process comprising:

(A) contacting said copper-bearing material with an effective amount of at least one aqueous leaching solution to dissolve copper ions in said leaching solution and form a copper-rich aqueous leaching solution;
(B-1) contacting said copper-rich aqueous leaching solution from step (A) with an effective mount of at least one copper-bearing water-insoluble extractant from step (C-2) to transfer copper ions from said copper-rich aqueous leaching solution to said copper-bearing extractant to form a copper-rich extractant and a first copper-depleted aqueous leaching solution;
(C-1) separating said copper-rich extractant from said first copper-depleted aqueous leaching solution, advancing said copper-rich extractant to step (D);
(B-2) contacting said first copper-depleted aqueous leaching solution from step (C-1) with an effective mount of at least one copper-depleted extractant from step (E) to transfer copper ions from said first copper-depleted aqueous leaching solution to said copper-depleted extractant to form a copper-bearing extractant and a second copper-depleted aqueous leaching solution;
(C-2) separating said copper-bearing extractant from said second copper-depleted aqueous leaching solution, recirculating said copper-bearing extractant to step (B-1);
(D) contacting said copper-rich extractant from step (C-1) with an effective mount of at feast one aqueous stripping solution to transfer copper ions from said copper-rich extractant to said stripping solution to form a first electrolyte solution and a copper-depleted extractant;
(E) separating said first electrolyte solution from said copper-depleted extractant, recirculating said copper-depleted extractant to step (B-2);
(F) advancing said first electrolyte solution from step (E) to an electrolytic cell equipped with at least one first anode and at least one first cathode, said first electrolyte solution being characterized by a free chloride concentration of up to about 5 ppm, and applying an effective mount of voltage across said first anode and said first cathode to deposit copper powder on said first cathode;
(G) removing copper powder from said first cathode;
(H) dissolving said copper powder from step (G) in a sulfuric acid solution to form a second electrolyte solution and placing said second electrolyte solution in an electroforming cell equipped with a second anode and a second cathode, said second cathode being a rotating cathode;
(I) flowing said second electrolyte solution between said second anode and second cathode, and applying an effective amount of voltage across said second anode and second cathode to deposit copper foil on said second cathode;
and
(J) removing said copper foil from said second cathode.

10 more elements

A process for making cuprous oxide, cupric oxide or a mixture thereof from a copper-bearing material, said process including sequential steps (A), (B-1), (C-1), (B-2), (C-2), (D), (E), (F), (G) and (H'), said process comprising:

(A) contacting said copper-bearing material with an effective amount of at least one aqueous leaching solution to dissolve copper ions in said leaching solution and form a copper-rich aqueous leaching solution;
(B-1) contacting said copper-rich aqueous leaching solution from step (A) with an effective amount of at least one copper-bearing water-insoluble extractant from step (C-2) to transfer copper ions from said copper-rich aqueous leaching solution to said copper-bearing extractant to form a copper-rich extractant and a first copper-depleted aqueous leaching solution;
(C-1) separating said copper-rich extractant from said first copper-depleted aqueous leaching solution, advancing said copper-rich extractant to step (D);
(B-2) contacting said first copper-depleted aqueous leaching solution from step (C-1) with an effective amount of at least one copper-depleted extractant from step (E) to transfer copper ions from said first copper-depleted aqueous leaching solution to said copper-depleted extractant to form a copper-bearing extractant and a second copper-depleted aqueous leaching solution;
(C-2) separating said copper-bearing extractant from said second copper-depleted aqueous leaching solution, recirculating said copper-bearing extractant to step (B-1);
(D) contacting said copper-rich extractant from step (C-1) with an effective mount of at least one aqueous stripping solution to transfer copper ions from said copper-rich extractant to said stripping solution to form a first electrolyte solution and a copper-depleted extractant;
(E) separating said first electrolyte solution from said copper-depleted extractant, recirculating said copper-depleted extractant to step (B-2);
(F) advancing said first electrolyte solution from step (E) into an electrolytic cell equipped with at least one first anode and at least one first cathode, said first electrolyte solution being characterized by a free chloride concentration of up to about 5 ppm, and applying an effective mount of voltage across said first anode and said first cathode to deposit copper metal powder on said first cathode;
(G) removing copper metal powder from said first cathode;
and
(H') calcining said copper metal powder at a sufficient temperature and for an effective period of time to form cuprous oxide, cupric oxide or a mixture thereof.

8 more elements

A process for making copper foil from a copper-bearing material, said process including sequential steps (A), (B-1), (C-1), (B-2), (C-2), (D), (E), (F), (G), (H'), (H), (I) and (J), said process comprising:

(A) contacting said copper-bearing material with an effective amount of at least one aqueous leaching solution to dissolve copper ions in said leaching solution and form a copper-rich aqueous leaching solution;
(B-1) contacting said copper-rich aqueous leaching solution from step (A) with an effective mount of at least one copper-bearing water-insoluble extractant from step (C-2) to transfer copper ions from said copper-rich aqueous leaching solution to said copper-bearing extractant to form a copper-rich extractant and a first copper-depleted aqueous leaching solution;
(C-1) separating said copper-rich extractant from said first copper-depleted aqueous leaching solution, advancing said copper-rich extractant to step (D);
(B-2) contacting said fast copper-depleted aqueous leaching solution from step (C-1) with an effective mount of at least one copper-depleted extractant from step (E) to transfer copper ions from said first copper-depleted aqueous leaching solution to said copper-depleted extractant to form a copper-bearing extractant and a second copper-depleted aqueous leaching solution;
(C-2) separating said copper-beating extractant from said second copper-depleted aqueous leaching solution, recirculating said copper-bearing extractant to step (B-1);
(D) contacting said copper-rich extractant from step (C-1) with an effective amount of at least one aqueous stripping solution to transfer copper ions from said copper-rich extractant to said stripping solution to form a first electrolyte solution and a copper-depleted extractant;
(E) separating said first electrolyte solution from said copper-depleted extractant, recirculating said copper-depleted extractant to step (B-2);
(F) advancing said first electrolyte solution from step (E) into an electrolytic cell equipped with at least one first anode and at least one first cathode, said first electrolyte solution being characterized by a free chloride concentration of up to about 5 ppm, and applying an effective amount of voltage across said first anode and said first cathode to deposit copper metal powder on said first cathode;
(G) removing copper metal powder from said first cathode;
(H') calcining said copper metal powder to form cuprous oxide, cupric oxide or a mixture thereof;
and
(H) dissolving said cuprous oxide, cupric oxide or mixture thereof from step (H') in a sulfuric acid solution to form a second electrolyte solution and placing said second electrolyte solution in an electroforming cell equipped with a second anode and a second cathode, said second cathode being a rotating cathode;
(I) flowing said second electrolyte solution between said second anode and second cathode, and applying an effective amount of voltage across said second anode and second cathode to deposit copper foil on said second cathode;
and
(J) removing said copper foil from said second cathode.

12 more elements

A process for making copper metal powder from a copper-bearing material, said process including sequential steps (A), (B-1), (C-1), (B-2), (C-2), (E), (F) and (G), said process comprising:

(A) contacting said copper-bearing material with an effective amount of at least one aqueous leaching solution to dissolve copper ions in said leaching solution and form a copper-rich aqueous leaching solution;
(B-1) contacting said copper-rich aqueous leaching solution with an effective mount of at least one copper-bearing water-insoluble extractant from step (C-2) to transfer copper ions from said copper-rich aqueous leaching solution to said copper-bearing extractant to form a copper-rich extractant and a first copper-depleted aqueous leaching solution;
(C-1) separating said copper-rich extractant from said first copper-depleted aqueous leaching solution, advancing said copper-rich extractant to step (D);
(B-2) contacting said first copper-depleted aqueous leaching solution from step (C-1) with an effective amount of at least one copper-depleted extractant from step (E) to transfer copper ions from said first copper-depleted aqueous leaching solution to said copper-depleted extractant to form a copper-bearing extractant and a second copper-depleted aqueous leaching solution.
(C-2) separating said copper-bearing extractant from said second copper-depleted aqueous leaching solution, recirculating said copper-bearing extractant to step (B-1);
(D) contacting said copper-rich extractant from step (C-1) with an effective mount of at least one aqueous stripping solution to transfer copper ions from said copper-rich extractant to said stripping solution to form a first electrolyte solution and a copper-depleted extractant;
(E) separating said first electrolyte solution from said copper-depleted extractant, recirculating said copper-depleted extractant to step (B-2);
(F) advancing said first electrolyte solution to an electrolytic cell equipped with at least one first dimensionally stable insoluble anode and at least one first cathode, said first electrolyte solution being characterized by the presence of at least one triazole and by a free chloride concentration of up to about 5 ppm, and applying an effective amount of voltage across said first anode and said first cathode to deposit copper powder on said first cathode;
and
(G) removing copper metal powder from said first cathode.

7 more elements

Dependencies are inferred from the claim text.

Process for making copper metal powder, copper oxides and copper foil

Life of this patent

Process for making copper metal powder, copper oxides and copper foil

Life of this patent

Abstract

Claims31