Resource and energy efficient process technologies
The improvement in KPIs in a scheelite processing plant after using our optimised process conditions
Source: Ben Said, Borhane, Lucas Pereira
Scaling-up processes into pilot and industrial scale is costly and time-consuming leading to losses, both in raw materials and capital. Operational, economic and environmental feasibility aspects are a crucial part of our research. We conduct our scale-up activities in our pilot facilities (Technology Readiness Level 4-6) with a profound understanding of how different parameters in the operation influence the process and innovative reagents.
Conceptualization of pilot trials
After thoroughly characterizing a new sample, a suitable processing route is designed to recover as much of its contained raw materials as possible. By using numerical optimization algorithms based on the fusion of high-dimensional data sets, we can largely minimize the number of tests required for reaching the optimal operating conditions. For that, we use for example an in-house developed online optimization tool. Automation and scalability of our technologies is achieved through online X-ray fluorescence spectroscopy (XRF) analyzers and mobile piloting units such as containerized hydrometallurgy plants.
Recycling 4.0
Automated semi pilot-scale flotation cell
Source: HIF
In laboratory and pilot trials a vast amount of data (big data) is generated. At HIF, we develop digital solutions for automatically collecting and storing data in findable, accessible, interoperable, and reusable (FAIR) formats. In the near future, we also plan to increase our expertise for the implementation of online detection of chemical/phase compositions in complex materials in a dynamic process under standard industrial conditions using spectroscopic systems.
Ultimately, these efforts will help to realize an infrastructure for the Recycling 4.0 - the FlexiPlant, a globally unique research facility for researching and developing flexible and sustainable technologies for mineral beneficiation and mechanical recycling. The FlexiPlant concept includes amongst others intelligent sensing, real-time analysis, automation and artificial intelligence for fast data processing and decision-making. It also integrates HIF’s metallurgy pilot plant for downstream processing and the generation of less complex and high purity raw materials.
Examples for upscaling infrastructures and successful upscaling processes:
- Pilot Plant trials for the Processing of a Complex Tin Ore: A Contribution towards Geometallurgy in Beneficiation
- Pilot-scale plasma arc melting furnace for the recycling of for example slags
- Containerized hydrometallurgical plant for mining tailings waste treatments
- DigiFloat: Delivering digitalization for the optimization of complex mineral processing routes
