ch4 Leaching

University of Baghdad
College of Engineering
Chemical Engineering Ch.4 Leaching
Leaching refer to the extracting of a soluble material (leachant, solute)

from a solid (inert, carrier, insoluble) by means of solvent (extractant).
The process may be employed either for the production of a

concentrated solution of evaluable solid material, or in order to free
an insoluble slid.
Note: Soluble material = solute or leachant, solid = insoluble, inert,

carrier, solvent = extract
Generally, the process can be considered in three parts: -
Firstly: The change of phase of the solute as it dissolves in the solvent.
Secondly: It’s diffusion through the solvent in the process of the solid
to the outside of the particle.
And Thirdly: The transfer of the solute from the solution in contact
with the particles to the main bulk of the solution (external diffusion).
Any of these processes may be responsible for limiting the extraction rate.
1
Dr. Wadood T. Mohammed & Sarmad A. Rashid
‫‪University of Baghdad‬‬
‫‪College of Engineering‬‬
‫‪Chemical Engineering‬‬ ‫‪Ch.4 Leaching‬‬
‫‪Leaching occurs in two steps:‬‬
‫‪1- Leacting: contacting solvent and solid to affect a transfer of a‬‬

‫‪solute (i.e the three steps dissolve, internal and external diffusion).‬‬
‫‪2- Washing: separation of solution from the remaining solid.‬‬
‫(‪ )leaching‬هي عملية استخالص مادة سائلة من داخل مادة صلبة بواسطة مذيب سائل مثل‬
‫استخالص الذهب من الصخور و استخالص الزيوت من النباتات وغسل الطابوق الزالة االمالح‬
‫وكذلك عملية اعداد الشاي‪ .‬الهدف هو اما استخالص مادة سائلة مرغوبة و ثمينة من داخل مادة‬
‫صلبة او تنقية المادة الصلبة مما في داخلها من مادة سائلة غير مرغوبة‪ .‬البد من تكسير المادة‬
‫الصلبة لكي تزداد مساحة التالمس و تزداد الطرق المؤدية الى التقاء المذيب بالمذاب‪.‬‬
‫هنا تتم العملية بمرحلتين‪:‬‬
‫اوالً‪ :‬عملية ال (‪ )leaching‬وتتم بثالث خطوات‪:‬‬
‫‪ ‬وصول المذيب الى المذاب داخل الفراغات‪.‬‬
‫‪ ‬انتشار المذاب في المذيب والخروج من الفراغات الى سطح الجزيئات وهذا يسمى‬
‫االنتشار الداخلي (‪.)internal diffusion‬‬
‫‪ ‬انتشار وانتقال المحلول (المذاب والمذيب) من السطح الخارجي للجزيئة الى الوسط‬
‫المستقر (‪ )bulk‬وهذا يسمى االنتشار الخارجي (‪.)external diffusion‬‬
‫ثانياً‪ :‬عملية الغسل (‪ )washing‬وهي فصل المحلول عن المادة الصلبة‪.‬‬
‫‪Modes of the operation:‬‬
‫‪I – Batch leaching‬‬
‫‪II – Continuous leaching‬‬ ‫‪co-current‬‬

‫‪counter‬‬
‫‪cross–current‬‬
‫‪current‬‬
‫‪constant under flow‬‬ ‫‪variable under flow‬‬
‫‪2‬‬
‫‪Dr. Wadood T. Mohammed & Sarmad A. Rashid‬‬
1- Batch Leaching:
When the solids to be leached are in the form of fine particles perhaps
smaller than 0.1mm in diameter, batch leaching in conveniently
conducted in an agitated vessel.
C at liquid bulk
CS
Step1: Leaching:
𝑫𝑳
̅̅̅̅
𝑵𝑨 = .A (CS – C) (1) Mass transfer equation
𝒃
due to eddy diffusion
̅̅̅̅
𝑵𝑨 = 𝑲𝑳 . 𝑨(𝑪𝑺 − 𝑪)
𝒅𝑴 𝒅𝒄𝒗
= In batch process, we can
𝒅𝒕 𝒅𝒕
express M.T. by dM/dt
𝒅𝒄
𝒗 𝒅𝒕 = KL . A (CS – C) (2)
𝒄 𝒕
𝒅𝒄 𝑲𝑳 . 𝑨
∫ =∫ 𝒅𝒕
𝒐 𝑪𝒔 − 𝑪 𝒐 𝒗
3
𝒄 𝑲𝑳 .𝑨
- ln (CS – C ) = t
𝟎 𝒗
𝑪𝒔 − 𝑪 −𝑲𝑳 . 𝑨
𝐥𝐧 = 𝒕
𝑪𝒔 𝒗
𝑪𝒔 − 𝑪 −𝑲𝑳 .𝑨
= 𝒆 𝒗 𝒕
𝑪𝒔
𝑪 −𝑲𝑳 .𝑨
𝒕
𝟏− =𝒆 𝒗
𝑪𝒔
−𝑲𝑳 .𝑨
𝒕 In these relations,
C = CS [ 1- 𝒆 𝒗 ] (3)
the variables terms
are the concentration
C and time t, so we
−⍺ can calculate C at
𝒕
C = CS [ 1-𝒆 𝒗 ] (4) any t or opposite
Where:
C = concentration of the solute in the bulk of the solution at time (t)

(kg/𝐦𝟑 )
Cs = concentration of the saturated solution in contact with the

particles (kg/𝐦𝟑 )
𝐊 𝐋 = 𝐌. 𝐓. 𝐂 (m/s) → KL = DL/b
v = volume of solution (𝐦𝟑 )
b = effective thickness of the liquid film surrounding the particles (m)
⍺ = constant (m3/s) → ⍺ = KL . A
4
Step2: Number of washings:
𝟏
θN = (5)
(𝟏+𝜷)𝑵
or
𝐥𝐨𝐠𝜽𝟏
𝑵
N= (6)
𝐥𝐨𝐠(𝟏+𝜷)
Where:
N = number of washings.
Β = solvent decentered (‫ )المسحوب‬per solvent remaining in the insoluble

solids.
θn = is the fraction of solute remaining with the residue from the

original after the leaching.
𝑺𝒏 ‫كمية المذاب النهائية المتبقية مع الصلب بعد انتهاء الغسالت‬

θn = = (7)
𝑺 𝒍𝒆𝒂𝒄𝒉𝒊𝒏𝒈 ‫كمية المذاب االبتدائية الموجودة مع الصلب بعد عملية‬
5
Example 1:
500 kg of solid containing 28% by mass of water soluble solid A is
agitated in a vessel with 100m3 water for 600 sec. After each decanting
25% of a solution produced remain in the residue. Water is saturated
with A at a concentration of 2.5 kg/m3. Find:
1) The concentration of A in the solution after leaching.

2) Number of washes such that the concentration of A in the solid
residue is 0.01% by mass (dry basis).
Given that form a pilot test in a tank of 1 m3 volume showed that
75% saturation attained in 10 sec.
Solution:
1) Form a pilot test, we find ⍺ :-
−⍺
𝒕
C = Cs [ 1-𝒆 𝒗 ]
−⍺
𝟏𝟎
0.75C = Cs [ 1-𝒆 𝟏 ]
∝= 𝟎. 𝟏𝟑𝟖 m3/s
∝
−𝒗 𝒕
C = Cs ( 1- 𝒆 )
𝟎.𝟏𝟑𝟖
− (𝟔𝟎𝟎)
C = 2.5 ( 1- 𝒆 𝟏𝟎𝟎 )
C= 1.4 kg/m3
NOTES: :‫المالحظات‬
‫ لمعرفة هل العملية كفوءة ام ال‬:ً‫أوال‬
)500 * 0.28 = 140 kg( ‫نحسب كمية المادة الداخلة وهنا تساوي‬
)C = 140/100 = 1.4 kg/m3( ‫ثم نقسمها على الحجم فنحصل على التركيز‬
‫ بالقانون أعاله‬600s ‫ثم نقارن بين التركيز المحسوب هنا و التركيز المحسوب بعد‬
.‫ فالعملية تكون كفوءة‬،‫) فاذا كانت القيمتان متساويتان‬C= 1.4 kg/m3(
‫) كافي إلجراء العملية؟‬600s( ‫ هل الزمن‬:‫أو قد يأتي السؤال بصيغة‬
6
‫‪NOTES:‬‬ ‫المالحظات‪:‬‬
‫ثانيا ً‪ :‬ماذا لو كان السؤال‪ :‬ماهو الزمن المثالي إلنجاز العملية؟‬
‫نعيد الحسابات بشكل آخر (‪)500 * 0.28 = 140 kg‬‬
‫وباستخدام حجم مذيب ‪ 100m3‬نحصل على التركيز(‪)C=140/100 = 1.4 kg/m3‬‬
‫نعود اآلن الى القانون الرئيسي ونعوض جميع األرقام عدى الزمن الذي نجده من‬
‫‪−⍺‬‬
‫𝒕‬
‫𝒆‪C = Cs [ 1-‬‬ ‫] 𝒗‬ ‫القانون الرئيسي ويمثل الزمن المثالي‪:‬‬
‫‪2) Number of washing‬‬
‫‪B = 500 * 0.72 = 360 kg‬‬
‫𝒏𝑺‬
‫‪0.01‬‬ ‫=‬
‫𝒏𝑺‪𝟑𝟔𝟎 +‬‬
‫‪0.02‬‬ ‫‪Sn = 0.036 kg‬‬
‫𝒈𝒌‬
‫‪S = 1.4‬‬ ‫*‬ ‫‪100 m3 * 0.25 = 35 kg‬‬
‫𝟑𝒎‬
‫𝒏𝒔‬ ‫𝟔𝟑𝟎‪𝟎.‬‬
‫= ‪Ɵn‬‬ ‫=‬ ‫‪= 1.028 * 10-3‬‬
‫𝒔‬ ‫𝟓𝟑‬
‫𝟓𝟕‬
‫=‪B‬‬ ‫‪=3‬‬
‫𝟓𝟐‬ ‫هنا طريقة إليجاد (‪)S‬عند الزمن الكافي‪:‬‬
‫𝟏‬
‫𝒈𝒐𝒍‬ ‫‪If the time used is enough, we can say:‬‬
‫𝒏𝜽‬
‫=‪n‬‬
‫)𝜷‪𝒍𝒐𝒈(𝟏−‬‬ ‫‪S = 500 * 0.28 * 0.25 = 35 kg‬‬
‫𝟏‬
‫𝒈𝒐𝒍‬
‫𝟑‪𝟏.𝟎𝟐𝟖∗𝟏𝟎−‬‬
‫=‪n‬‬
‫)𝟑‪𝒍𝒐𝒈(𝟏+‬‬
‫𝟓 ≃ ‪n = 4.96‬‬
‫‪7‬‬
2. Continues Leaching
A: Counter Current Flow Continuous Leaching
V1, L1 V2, L2 V3, L3 Vn, Ln Vn-1,Ln-1 VN, LN VN+1,LN+1

1 2 n N
So, Wo S1, W1 S2, W2 Sn-1,Wn-1 Sn,Wn SN-1,WN-1 SN,WN
Note: under flow: the mixture of insoluble residue and solution

over flow: the liquid (solute and solvent) referred to over flow
L: flow rate of solute in over flow kg/s
S: flow rate of solute in under flow kg/s
V: flow rate of solution in over flow kg/s
W: flow rate of solution in under flow kg/s
Case I: Constant under flow
Constant under flow: means the quantity of solvent or solution

removed in association with the insoluble solids has been assumed to
be constant and independent of the concentration of solute in the
solution in the thickener.
Define R:
𝒂𝒎𝒐𝒖𝒏𝒕 𝒐𝒇 𝒔𝒂𝒍𝒖𝒕𝒆 𝒅𝒊𝒔𝒄𝒉𝒂𝒓𝒈𝒆 𝒊𝒏 𝒐𝒗𝒆𝒓 𝒇𝒍𝒐𝒘 𝑳
R= = 𝑺
(8)
𝒂𝒎𝒐𝒖𝒏𝒕 𝒐𝒇 𝒔𝒂𝒍𝒖𝒕𝒆 𝒅𝒊𝒔𝒄𝒉𝒂𝒓𝒈𝒆 𝒊𝒏 𝒖𝒏𝒅𝒆𝒓 𝒇𝒍𝒐𝒘
OR:
𝒂𝒎𝒐𝒖𝒏𝒕 𝒐𝒇 𝒔𝒂𝒍𝒖𝒕𝒆 𝒅𝒊𝒔𝒄𝒉𝒂𝒓𝒈𝒆 𝒊𝒏 𝒐𝒗𝒆𝒓 𝒇𝒍𝒐𝒘 𝑽
R= = 𝑾
(9)
OR:
𝒂𝒎𝒐𝒖𝒏𝒕 𝒐𝒇 𝒔𝒂𝒍𝒖𝒕𝒆 𝒅𝒊𝒔𝒄𝒉𝒂𝒓𝒈𝒆 𝒊𝒏 𝒐𝒗𝒆𝒓 𝒇𝒍𝒐𝒘 𝑽−𝑳
R= = 𝑾−𝑺
(10)
8
Now to calculate N, we will derive this relation:
Ln, Vn Ln+1, Vn+1

n
Sn-1, Wn-1, Bo Sn, Wn, Bo
M.B on stage n (soluse M.B)
𝑺𝒏−𝟏 + 𝑳𝒏+𝟏 = 𝑳𝒏 + 𝑺𝒏
𝑺𝒏−𝟏 + 𝑹𝑺𝒏+𝟏 = 𝑹𝑺𝒏 + 𝑺𝒏
.
𝑺𝑵 𝑹−𝟏
=
𝑺𝒐 𝑹𝑵+𝟏 −𝟏
𝑺𝑵
f = or f = 1- recovery
𝑺𝒐
𝑹−𝟏
𝐥𝐨𝐠[ 𝟏+ ]
𝒇
N= =1 (11)
𝒍𝒐𝒈𝑹
9
Example 2:
1.6 kg/s of Sand – Salt mixture containing 62.5% sand is leached with
0.5 kg/s water in a counter current and the residue from each stage
contain 0.25kg water/kg insoluble solid. Fined the number of stages in
order that sand should contain 10% salt when dried.
𝑺𝑵
0.1 =
𝑺𝑵+𝑩
Solution:
B = 1.6 * 0.625 = 1 kg/s
So = 1.6 – 1 = 0.6kg/s or [ So = 1.6*0.375 = 0.6 ]
𝑽𝑵+𝟏 = 0.5kg/s (pure solvent → 𝑳𝑵+𝟏 = 0)

𝑲𝒈 𝒘𝒂𝒕𝒆𝒓
W- Sn = 0.25 * (1)kg insoluble = 0.25 kg/s
𝑲𝒈 𝒊𝒏 𝒔𝒐𝒍𝒖𝒃𝒍𝒆
𝑺𝑵 𝑺𝑵
0.1 = → 0.1 =
𝑺𝑵 +𝑩 𝑺𝑵 +𝑩
SN = 0.11 kg/s
𝒔𝒐𝒍𝒗𝒆𝒏𝒕 𝒐𝒗𝒆𝒓 𝒇𝒍𝒐𝒘 𝒗−𝒍 𝟎.𝟓
R= = = =2
𝒔𝒐𝒍𝒗𝒆𝒏𝒕 𝒖𝒏𝒅𝒆𝒓 𝒇𝒍𝒐𝒘 𝒘−𝒔 𝟎.𝟐𝟓
𝑺𝑵 𝟎.𝟒
f = = = 0.183
𝑺𝒐 𝟎.𝟔
𝑹−𝟏
𝐥𝐨𝐠(𝟏+ 𝒇 )
N= - 1
𝐥𝐨𝐠 𝑹
𝟐−𝟏
𝐥𝐨𝐠(𝟏+𝟎.𝟏𝟖𝟑)
N= -1
𝐥𝐨𝐠 𝟐
N = 1.69 ≈ 2 stage of washing
10
Case II: Variable under flow:
Variable under flow: amount of solvent or solution in the under flow

is a function of the concentration of the solution (X)
𝑲𝒈 𝑺𝒐𝒍𝒖𝒕𝒆
1- First one calculate X ( ) from each stage:
𝑲𝒈 𝑺𝒐𝒍𝒖𝒂𝒕𝒊𝒐𝒏
L1 L2 L3 Ln Ln+1 LN-1 LN LN+1

V1 V2 V3 Vn Vn+1 VN-1 VN VN+1
1 2 n N-1 N
So S1 S2 Sn-1 Sn SN-2 SN-1 SN
Wo W1 W2 Wn-1 Wn WN-2 WN-1 WN
Bo Bo Bo
Solute M.B
𝑺𝒏−𝟏 + 𝑳𝑵+𝟏 = 𝑳𝒏 + 𝑺𝑵
𝑳𝒏 = 𝑳𝑵+𝟏 + 𝑺𝒏−𝟏 -𝑺𝒏 …..(a)
Solution MB
𝑾𝒏−𝟏 + 𝑽𝑵+𝟏 = 𝑽𝒏 + 𝑾𝑵
𝑽𝒏 = 𝑽𝑵+𝟏 + 𝑾𝒏−𝟏 − 𝑾𝑵 ….(b)
Divided (a) by (b)
𝑳𝒏 𝑳𝑵+𝟏 +𝑺𝒏−𝟏 −𝑺𝑵
=
𝑽𝑵 𝑽𝑵+𝟏 +𝑾𝒏−𝟏 −𝑾𝑵
𝑳𝑵+𝟏 +𝑺𝒏−𝟏 −𝑺𝑵

Xn = (12)
𝑽𝑵+𝟏 +𝑾𝒏−𝟏 −𝑾𝑵
2- Second One S=WX
Where:
𝑲𝒈 𝑺𝒐𝒍𝒖𝒕𝒆 𝑲𝒈 𝑺𝒐𝒍𝒖𝒂𝒕𝒊𝒐𝒏
X= , W=
𝑲𝒈 𝑺𝒐𝒍𝒖𝒕𝒊𝒐𝒏 𝑲𝒈 𝒊𝒏𝒔𝒐𝒍𝒖𝒃𝒍𝒆 𝒔𝒐𝒍𝒊𝒅
11
‫‪3- Third One: from experiment data‬‬
‫‪Amount of solution in under flow‬‬ ‫‪Amount of solute in solution‬‬
‫)‪(kg) solution (w‬‬ ‫)‪kg solute/kg solution (x‬‬
‫‪-‬‬ ‫‪-‬‬
‫‪} ∆w‬‬ ‫‪} ∆x‬‬
‫‪-‬‬ ‫‪-‬‬
‫‪-‬‬ ‫‪-‬‬
‫‪} ∆w‬‬ ‫‪} ∆x‬‬
‫‪-‬‬ ‫‪-‬‬
‫المالحظات‪:‬‬
‫أوالً‪ :‬اذا كانت المعلومات اعاله (عند رسمها) تمثل خط مستقيم بين ‪ W‬و ‪ X‬عندها‬
‫𝑾∆‬
‫) والمقطع الصادي (‪ )intercept‬والذي قيمته عند (‪ )X=0‬فتكون‬ ‫نأخذ الميل (‬
‫𝑿∆‬
‫لدينا معادلة خط مستقيم (‪ .)w = mx + c‬ولنا الخيار هنا بإطمال الحل بالرسم او‬
‫بالمعادلة‪.‬‬
‫ثانيا ً‪ :‬اذا كانت المعلومات اعاله (عند رسمها) تمثل منحني فيجب ان نرسم‪ .‬وهنا‬
‫نستطيع ان نكون في جدول المعلومات عمود ثالث يمثل (‪ )s = w x‬وممكن رسمها‬
‫كذلك‪.‬‬
‫‪w vs x‬‬
‫‪w‬‬ ‫‪s‬‬
‫‪s vs x‬‬
‫‪x‬‬
‫‪12‬‬
Example 3:
A vegetable seed marital containing solute (So) 0.4 kg oil/1g insoluble
solid is washed with hydrocarbon solvent in order to recover 90% of
the oil in a counter current unit. It’s found that the under flow varies
with the concentration of classifiers as given below:
Amount of solution in under flow(w) Concertrmation of solute in solution(x)
kg solution/kg in soluble solid kg solvent/kg solution
0.3 0
0.32 0.1
0.34 0.2
0.36 0.3
0.38 04
0.4 0.5
If the solvent input flow is 0.5 kg/kg insoluble solid. Find the number
of stage required?
Solution:
Basis 1kg insoluble solid )basis = 1kg( ‫) فنأخذ‬insoluble solid( ‫يعط قيمة‬
ِ ‫اذا لم‬
‫حتى تبقى االرقام كما هي‬
𝑳𝑵+𝟏 +𝑺𝒏−𝟏 −𝑺𝑵
Xn =
𝑽𝑵+𝟏 +𝑾𝒏−𝟏 −𝑾𝑵
LN+1,VN+1,SN,WN ( these terms should be found)

LN+1 = 0 (pure solvent)
SN = So (1-recovery) =0.4 (1-0.9) = 0.04kg/s
VN+1 = 0.5 kg/s (only solvent in over flow) ‫) من خالل جدول المعلومات المعطاة بالسؤال‬wn( ‫حساب‬
‫ نرسم المعلومات بعد اكمال الجدول‬.1
W X S
----- ----- -----
0.3 0 0
0.32 0.1 0.032 W S
0.34 0.2 0.068
0.36 0.3 0.108
0.38 0.4 0.152
0.4 0.5 0.2
From plot SN = 0.04 = WN = 0.325 kg/s XX

13
،‫ لكون المعلومات المعطاة تمثل خط مستقيم‬.2

‫نستطيع التعبير عنها بمعادلة خط مستقيم كمايلي‬
WN = 0.2 XN + 0.3
𝑺𝑵 𝟎.𝟎𝟒
WN = 0.2 ( ) + 0.3 = 0.2( ) + 0.3
𝑾𝑵 𝑾𝑵
WN2 = 0.3WN – 0.008
𝟎.𝟑 ± √(𝟎.𝟑)𝟐 −𝟒(𝟎.𝟎𝟎𝟖)

WN =
𝟐
WN = 0.3246 kg/s
𝟎 − 𝟎.𝟎𝟒 + 𝑺𝒏−𝟏
XN =
𝟎.𝟓 − 𝟎.𝟑𝟐𝟓 + 𝑾𝒏−𝟏
𝑺𝒏−𝟏 −𝟎.𝟎𝟒
Xn= ……1
𝑾𝒏−𝟏 +𝟎.𝟏𝟕𝟓
Wn = 0.2 Xn+0.3 ……2
Sn=Xn Wn …………3
So → X1 → W1 → S1
If S1> 𝑺𝑵 continue
If S1≤ 𝑺𝑵 then no. of stages = 1
𝑺𝒐−𝟎.𝟎𝟒 𝟎.𝟒−𝟎.𝟎𝟒
So = X1 = = = 𝟎. 𝟔𝟐𝟔
𝑾𝒐+𝟎.𝟏𝟕𝟓 𝟎.𝟒+𝟎.𝟏𝟕𝟓
X1 = 0.626 → W1 = 0.2X1 + 0.3 = 0.2(0.626) + 0.3 = 0.425
W1 = 0.425 → S1 = X1W1 = 0.626(0.425) = 0.266
S1>SN ⸫ continue
14
S1 = 0.286 => X2 = 0.376
W1 = 0.425
X2 = 0.376 → W2 = 0.375
W2 = 0.375 → S2 = 0.141
S2>SN ⸫ continue
S2 = 0.141 → X3 = 0.183
W2 = 0.375
X3 = 0.183 → W3 = 0.3366
W3 = 0.3366 → S3 = 0.0615
S3>SN ⸫ continue
S3 = 0.0615
X4 = 0.042
W3 = 0.336
X4 = 0.042 → W4 = 0.3084
W4 = 0.3084 → S4 = 0.0129
Now S4<SN
No. of stages = 4
15
B: Cross-Current Continuous Leaching:
Example 4:
Cod liver oil to be extracted from ground up cool fish head, containing
25% oil and 75% insoluble solids, the leaching operating is to be done
in across-flow apparatus consisting of the equivalent of three
equilibrium stages, 1000kg/hr of fish head is fed into the system and
the under flow contains 0.2kg solution/kg insoluble solid, if 300kg/hr
of hexane is added to each stage. Determine the percentage of oil
remaining in fish head leaving the system.
Solution:
300kg/hr 300kg/hr 300kg/hr
1000kg/hr X1 X2 X3
X1 X2 X3
So = 25% S1 S2 S3
BO = 75% W1 W2 W3
BO BO BO
M1 M2 M3
Stage1:
Insoluble solid
Bo = 0.75(1000) = 750 kg/hr
So = 0.25(1000) = 250 kg/hr

𝟐𝟓𝟎
X1 = = 0.8333
𝟑𝟎𝟎
𝑾𝟏 = 0.2(750) = 150 kg/hr
16
Exit from stage 1 is:
S1 = X1 W1 = 0.8333(150) = 125 kg/hr
B = 750 kg/hr
W1 = 150 kg/hr
Stage2:
𝟏𝟐𝟓
𝑿𝟐 = = 𝟎. 𝟐𝟕𝟕
𝟏𝟓𝟎 + 𝟑𝟎𝟎
𝑾𝟐 = 𝟏𝟓𝟎 𝒌𝒈/𝒉𝒓
𝑺𝟐 = 𝑿𝟐 𝑾𝟐 = 0.277(150) = 41.55 kg/hr
Exit from stage 2 is:
𝑺𝟐 = 𝟒𝟏. 𝟓𝟓𝒌𝒈/𝒉𝒓
B = 750 kg/hr
𝑾𝟐 = 𝟏𝟓𝟎𝒌𝒈/𝒉𝒓
Stage3:
𝟒𝟏. 𝟓𝟓
𝑿𝟑 = = 𝟎. 𝟎𝟗𝟐𝟑
𝟏𝟓𝟎 + 𝟑𝟎𝟎
𝑺𝟑 = 𝑿𝟑 𝑾𝟑 = 0.0923(150) = 13.85 kg/hr
𝑺𝑵 𝟏𝟑.𝟖𝟓
F= = = 0.0554
𝑺𝒐 𝟐𝟓𝟎
% remaining = 5.54%
17
Example 5:
Solid feed of 150kg/hr containing 0.333 water soluble Na2CO3 and

0.667 insoluble ash is to be leached and washed at 30C in two-stage,
counter current system with 400kg/hr of water. The leaching stage of
an agitated vessel that discharges slurry into a thickener. The washing
stage consists of a second thickener. Experiments show that the sludge
under flow from each stage will contain 2kg solution/kg insoluble ash.
Given:at 30C solubility of carbonate in water is 38.8kg/100kg of water.
a. Calculate the % recovery of carbonate in the final extract.

b. If a third stage is added calculate the additional carbonate recovery.
c. Calculate the % recovery if 50% carbonate is leached in the first
stage and the remaining in the second stage. Leaving only the last
stage as a true washing stage.
Solution:
LL, VL L1, V1 L2, V2
L 1
Bo, So, Wo Bo, SL, WL Bo, S1, W1
Bo = 0.667(150) = 100 kg/hr of insoluble ash Note: from the solubility, there
So = 0.333(150) = 50 kg/hr is sufficient water to dissolve all
the carbonate in leaching stage
Wo = 50 kg/h
𝑾𝑳 = 𝑾𝟏 = 2*Bo = 2*100 = 200 kg/h
Solute M.B. on washing stage (1):
𝑾𝑳 + 𝑽𝟐 = 𝑾𝟏 + 𝑽𝟏
𝑽𝟏 = 𝑾𝑳 + 𝑽𝟐 − 𝑾𝟏
V1 = 200 + 400 – 200 = 400 kg/hr
18
Solute M.B. on leaching stage (L):
𝑾𝒐 + 𝑽𝟏 = 𝑾𝑳 + 𝑽𝑳
𝑽𝑳 = 𝑾𝒐 + 𝑽𝟏 − 𝑾𝑳
VL = 50 + 400 - 200 = 250 kg/hr
Now:
Solute M.B on stage (1):
𝑿𝑳 𝑾𝑳 = 𝒚𝟏 𝒗𝟏 + 𝑿𝟏 𝑾𝟏
200𝑿𝑳 = 𝟒𝟎𝟎𝒚𝟏 + 𝟐𝟎𝟎𝑿𝟏
But 𝒚𝟏 = 𝑿𝟏 (indeed stage)
𝑿𝑳 = 𝟑𝑿𝟏 …………… (1)
Solute M.B on leaching stage (1):
𝑺𝒐 + 𝒚𝟏 𝒗𝟏 = 𝒚𝑳 𝒗𝑳 + 𝑿𝑳 𝒘𝑳
50 + 400y = 250𝒚𝑳 + 𝟐𝟎𝟎𝑿𝑳
But 𝒚𝟏 = 𝑿𝟏 and 𝒚𝑳 = 𝑿𝑳
X1 = 1.125 XL – 0.125 …………… (2)
Solving (1) and (2)
𝑿𝑳 = 𝟎. 𝟏𝟓𝟖 = 𝒚𝑳
𝑿𝟏 = 𝟎. 𝟎𝟓𝟐𝟔
𝑳𝑳 𝒚 𝑳 𝒗𝑳 𝟎.𝟏𝟓𝟖(𝟐𝟓𝟎)
% Recovery = = =
𝑺𝒐 𝑺𝒐 𝟓𝟎
% Recovery = 0.79 Or 79%
19

ch4 Leaching

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ch4 Leaching

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University of Baghdad

Leaching refer to the extracting of a soluble material (leachant, solute)

The process may be employed either for the production of a

Note: Soluble material = solute or leachant, solid = insoluble, inert,

Generally, the process can be considered in three parts: -

Firstly: The change of phase of the solute as it dissolves in the solvent.

‫‪Leaching occurs in two steps:‬‬

‫‪1- Leacting: contacting solvent and solid to affect a transfer of a‬‬

‫‪Modes of the operation:‬‬

‫‪I – Batch leaching‬‬

‫‪II – Continuous leaching‬‬ ‫‪co-current‬‬

‫‪constant under flow‬‬ ‫‪variable under flow‬‬

C = concentration of the solute in the bulk of the solution at time (t)

Cs = concentration of the saturated solution in contact with the

v = volume of solution (𝐦𝟑 )

b = effective thickness of the liquid film surrounding the particles (m)

Step2: Number of washings:

Β = solvent decentered (‫ )المسحوب‬per solvent remaining in the insoluble

θn = is the fraction of solute remaining with the residue from the

𝑺𝒏 ‫كمية المذاب النهائية المتبقية مع الصلب بعد انتهاء الغسالت‬

1) The concentration of A in the solution after leaching.

‫) كافي إلجراء العملية؟‬600s( ‫ هل الزمن‬:‫أو قد يأتي السؤال بصيغة‬

‫نعيد الحسابات بشكل آخر (‪)500 * 0.28 = 140 kg‬‬

‫وباستخدام حجم مذيب ‪ 100m3‬نحصل على التركيز(‪)C=140/100 = 1.4 kg/m3‬‬

‫‪2) Number of washing‬‬

‫‪B = 500 * 0.72 = 360 kg‬‬

A: Counter Current Flow Continuous Leaching

V1, L1 V2, L2 V3, L3 Vn, Ln Vn-1,Ln-1 VN, LN VN+1,LN+1

Note: under flow: the mixture of insoluble residue and solution

Constant under flow: means the quantity of solvent or solution

Now to calculate N, we will derive this relation:

Ln, Vn Ln+1, Vn+1

M.B on stage n (soluse M.B)

𝑺𝒏−𝟏 + 𝑹𝑺𝒏+𝟏 = 𝑹𝑺𝒏 + 𝑺𝒏

B = 1.6 * 0.625 = 1 kg/s

So = 1.6 – 1 = 0.6kg/s or [ So = 1.6*0.375 = 0.6 ]

𝑽𝑵+𝟏 = 0.5kg/s (pure solvent → 𝑳𝑵+𝟏 = 0)

N = 1.69 ≈ 2 stage of washing

Case II: Variable under flow:

Variable under flow: amount of solvent or solution in the under flow

L1 L2 L3 Ln Ln+1 LN-1 LN LN+1

𝑳𝑵+𝟏 +𝑺𝒏−𝟏 −𝑺𝑵

2- Second One S=WX

‫‪3- Third One: from experiment data‬‬

‫‪Amount of solution in under flow‬‬ ‫‪Amount of solute in solution‬‬

‫)‪(kg) solution (w‬‬ ‫)‪kg solute/kg solution (x‬‬

LN+1,VN+1,SN,WN ( these terms should be found)

From plot SN = 0.04 = WN = 0.325 kg/s XX

،‫ لكون المعلومات المعطاة تمثل خط مستقيم‬.2

WN2 = 0.3WN – 0.008

𝟎.𝟑 ± √(𝟎.𝟑)𝟐 −𝟒(𝟎.𝟎𝟎𝟖)

Wn = 0.2 Xn+0.3 ……2

If S1≤ 𝑺𝑵 then no. of stages = 1

X1 = 0.626 → W1 = 0.2X1 + 0.3 = 0.2(0.626) + 0.3 = 0.425

W1 = 0.425 → S1 = X1W1 = 0.626(0.425) = 0.266

S1 = 0.286 => X2 = 0.376

B: Cross-Current Continuous Leaching:

300kg/hr 300kg/hr 300kg/hr

Bo = 0.75(1000) = 750 kg/hr

So = 0.25(1000) = 250 kg/hr

𝑾𝟏 = 0.2(750) = 150 kg/hr

Exit from stage 1 is:

S1 = X1 W1 = 0.8333(150) = 125 kg/hr

𝑺𝟐 = 𝑿𝟐 𝑾𝟐 = 0.277(150) = 41.55 kg/hr