METHOD FOR THE PURIFICATION OF ZINC SULPHATE ELECTROLYTE

Abstract: Monovalent ions, especially chloride, fluoride and thallium, are efficiently removed from ZnSO₄ electrolyte by electrodialysis using alternating monovalent anion permselective membranes and cation exchange membranes or monovalent cation permselective membranes. Electro­ dialysis is carried out under turbulent flow conditions, at up to 60°C, a differential membrane pressure of less than 150 kPa, a current density of 10 to 500 A/m², and a pH of less than 5.5. Where both chloride and fluoride are removed a pH of 3.5 to 5.5 is maintained. Deposition of manganese and zinc on the electrodes is minimized by at least one of a number of means including arranging the membranes such that the end membranes are monovalent anion permselective; selecting a large electrode rinse flow; adding a small amount of soluble antimony and/or cobalt to the rinse flow; and using a cathode made of a material that promotes hydrogen evolution over zinc deposition. The electrode compartments are preferably rinsed with a 0.1 to 1.0 M Na₂SO₄ solution at pH 0 to 4.

Description: This invention relates to a method for the purification of zinc sulphate electrolyte. More particularly this invention relates to the removal of monovalent ions from ZnSO₄ electrolyte by electro­ dialysis. In processes for the recovery of zinc from zinc sulphate solution by electrolysis, it is necessary to subject electrolyte to purification in order to reduce the content of impurities that have deleterious effects in electrolysis. It is particularly important to achieve adequate removal of chloride, fluoride and thallium. The ZnSO₄ purification process and the effects of various impurities are discussed in Mathewson C.H., Zinc - The Metal, Its Alloys and Compounds, 3rd Print, Reinhold Publishing Corporation, 1964, pp. 65-333. Chloride has been conventionally removed as CuCl as AgCl, or by solvent extraction. Chloride and fluoride have been removed by preleaching or by washing calcined concentrate, flue dust, and the like with sodium carbonate solution. The main disadvantages of these methods include incomplete removal of the halides, requiring additional complementary steps, and high costs. The removal of fluoride by washing solids with soda solution is expensive and will still result in fluoride ions being present in the purified ZnSO₄ electrolyte. The removal of ions from solutions could be carried out by methods that may include electrodialysis, which is well documented. These references, however, do not disclose the use of electrodialysis in the purification of ZnSO₄ electrolyte for the electrowinning of zinc, or the removal of chloride, fluoride and thallium from ZnSO₄ electrolyte by electrodialysis. We have now found that the halides as well as monovalent cations can be efficiently removed from ZnSO₄ electrolyte by electrodialysis. It is an object of this invention to provide an improved method of purifying zinc sulphate electrolyte. According to the invention there is provided a method for the purification of zinc sulphate electrolyte containing concentrations of monovalent cations including at least one cation chosen from the group consisting of thallium, sodium and potassium, and monovalent anions including at least one anion chosen from the group consisting of chloride and fluoride by electrodialysis, characterised in that the method comprises the steps of feeding zinc sulphate electrolyte to diluate cells of an electrodialysis unit comprising a multiplicity of alternating monovalent cation permselective exchange membranes and monovalent anion permselective exchange membranes, said membranes defining alternating diluate and concentrate cells, an anode compartment and a cathode compartment, an anode positioned in the anode compartment and a cathode positioned in the cathode compartment; rinsing said anode compartment and said cathode compartment with circulating rinse solutions; applying an electrical current between the anode and the cathode at a value such that the value of the corresponding current density is in the range of 10 to 500 A/m²; maintaining the temperature in the unit in the range of 0 to 60°C; feeding electrolyte at a pH having a value of less than about 5.5; passing flows of solutions through the diluate and concentrate cells at a linear velocity sufficient to maintain turbulent flow in said cells; withdrawing a diluate from said diluate cells as the purified zinc sulphate electrolyte with reduced concentrations of monovalent cations and monovalent anions. In one embodiment of this invention, ZnSO₄ electrolyte containing monovalent ions including chloride, fluoride, thallium, sodium and potassium ions, is passed through an electrodialysis unit to remove monovalent anions and monovalent cations. In this embodiment, the electrodialysis unit includes a number of alternating concentrate and diluate (depleted solution) compartments separated by alternating cationic and anionic membranes, and an anode and a cathode compartment containing an anode and a cathode, respectively. Furthermore in this embodiment, the anionic and cationic membranes are selected from suitable monovalent ion permselective membranes, or, when selective removal of monovalent cations such as thallium is not required, the cationic membranes can be selected from the generally available cationic membranes. Zinc and manganese deposition on the electrodes may be controlled by one or more of a number of means that include the controlling of the compositions and flow rate of an electrode rinse solution that is circulated through the anode and the cathode compartments; the arranging of the alternating membranes such that the anode compartment and cathode compartment are separated from the adjacent diluate compartments by a monovalent anion permselective membrane; the addition of a small amount of cobalt and/or antimony; and the use of a cathode material that favours hydrogen evolution over metal deposition. Because halide, especially fluoride, removal is pH dependent, the pH of the electrolyte may be carefully controlled within a predetermined range; a less strict control of pH is required when the anion removal is restricted to chloride. The electrodialysis may be carried out in one or more stages depending on the concentration of monovalent ions in the ZnSO₄ electrolyte to be purified and/or the desired level of these ions in the purified electrolyte. By choosing appropriate conditions, the method of the invention can result in the effective removal in one or more stages of 90% or better of the monovalent ions, especially chloride, fluoride and thallium from the ZnSO₄ electrolyte. The invention will now be described in detail. ZnSO₄ electrolyte from leaching zinc-containing materials with sulfuric acid is subjected to purification to remove undesirable ions and to make the electrolyte suitable for the electrowinning of zinc. The purification includes the so-called iron purification and the purification with zinc dust. The method according to the invention can be sued prior to or after zinc dust purification. ZnSO₄ electrolyte may contain monovalent ions such as chloride, fluoride, thallium, sodium and potassium, and multivalent ions such as zinc, sulphate, manganese, cobalt, nickel, copper, cadmium, antimony, arsenic, iron, magnesium and calcium. The method according to the invention is particularly useful for the removal of monovalent ions including at least one monovalent anion selected from the group consisting of chloride and fluoride and for the removal of monovalent cations including thallium. ZnSO₄ electrolyte, obained from the iron-­ purification or after zinc dust purification, is fed to an electrodialysis unit. The electrodialysis unit comprises a multiplicity of vertically arranged, alternating monovalent anion permselective exchange membranes and cation exchange membranes or monovalent cation permeselective exchange membranes, a cathode compartment and an anode compartment. The choice of membranes is important. When only monovalent anions are to be removed, a combination of monovalent anion permselective membranes and general cation exchange membranes (limited permselectivity for mono over multivalent cations) makes it possible to remove monovalent anions from the electrolyte. This combination of membranes can be advantageously used when monovalent cations are present in small amounts. When both monovalent anions and monovalent cations are to be removed, a combination of monovalent anion and monovalent cation permselective membranes is used. Such combination will, therefore, make it possible to separate monovalent from multivalent ions, and to concentrate the monovalent cations and the monovalent anions. The ZnSO₄ electrolyte thereby becomes depleted from these ions. We have found that suitable monovalent cationic permselective membranes are, for example, strongly acidic membranes which have a membrane matrix of a styrene di-vinyl benzene copolymer on a polyvinyl chloride base and possess sulphonic acid radicals (R-SO₃H) as active groups. The active groups comprise 3-4 milli-equivalents per gram of dry resin which is satisfactory to provide the desired selectivity for monovalent ions. In partaicular, we have found that suitable monovalent cationic permselective membranes are treated Selemion TM CMR, Selemion TM Experimental A (specially treated on one face) and Selemion TM Experimental B or Selemion TM CSR (both surfaces specially treated). If the object is to remove only monovalent anions such as chloride and fluoride ions, and not thallium and other monovalent cations, the choice of the cationic membrane can be extended to include others available on the market such, as for example, those with sulphonic acid radicals (R­ -SO₃ H) as the active groups at 3-5 milli-equivalents per gram of dry resin, e.g., Selemion TM CMV. Suitable monovalent anion permselective membranes are, for example, strongly basic membranes with quaternary ammonium active groups, such as, for example, derived from trimethylamine (for example, R-N(CH₂)₃.Cl), at 3-4 milli-equivalents per gram of dry resin, and having a matrix of a styrene di-vinyl benzene copolymer on a polyvinyl chloride base. Selemion TM ASV or ASR, which is permselective for monovalent anions, particularly chloride and fluoride ions, is particularly suitable. The Selemion TM membranes, which are manufactured by the Asahi Glass Company of Tokyo, Japan, have the desired properties. It is understood that membranes with similar properties produced by other manufacturers such as Neosepta TM CM-1, Neosepta TM CMS, Neosepta TM ACS, and Neosepta TM CLE-E membranes that are produced by the Tokuyama Soda Co. Ltd. of Japan, and Ionac TM MC-3470, produced by the Ionac Chemical Company, are similarly suitable and that the use of combinations of other membranes may yield the desired results. The alternating cationic and anionic membranes form a number of alternating diluate cells and concentrate cells which is situated between the anode compartment and the cathode compartment. The anode and cathode are made of suitable materials. For example, the anode can be made of platinum coated titanium and the cathode of stainless steel. The cathode can also be advantageously made of a material for which the hydrogen overvoltage is lowered, such as platinum coated titanium, in order to favour hydrogen evolution over the deposition of zinc. A source of direct current is connected to the electrodes. The ZnSO₄ electrolyte, preferably free of suspended solids, is fed to the diluate cells. Any suspended solids are removed to less than 5 ppm prior to electrodialysis. A depleted solution or diluate, i.e. a purified ZnSO₄ electrolyte, is withdrawn from the diluate cells. A concentate, i.e. a solution concentrated in monovalent ions, particularly chloride, fluoride and thallium ions, is withdrawn from the concentrate cells, preferably at a rate equal to the rate of the net water transfer from the diluate to the concentrate during the electrodialysis. It is important to maintain turbulent conditions in the concentrate and diluate cells. This can be achieved by passing solution through the cells at a sufficient rate. If desired, at least a portion of the diluate and at least a portion of the withdrawn concentrate may be circulated as feed to the diluate and concentrate cells respectively, mainly to ensure turbulent conditions, but also to achieve the desired removal and concentration of ions. During electrodialysis, water transport occurs by osmosis and electro-osmosis usually in opposing directions and at different rates. The net water transport generally occurs in the direction from the diluate to the concentrate cells. This water transport is sufficient, in most cases, to form concentrate stream flows adequate for withdrawal. In those cases wherein the net water transfer rate to the concentrate cells is less than the desired withdrawal rate of concentrate from the concentrate cells, it will be necessary to feed a receiving solution to the concentrate cells. For example the receiving solution may be chosen from water, dilute sulphuric acid and a dilute salt solution compatible with the general operation of the electrodialysis unit, such as, for example, a dilute sodium sulphate solution. In the cathode and anode compartments, the predominant reactions are hydrogen and oxygen evolution respectively, However, small amounts of manganese dioxide and zinc deposit on the anode and cathode, respectively. The deposition on the electrodes is undesirable and should be kept at a minimum. The deposition can be controlled and kept at a minimum by at least one of a number of means. The first is to arrange the membranes in the electrodialysis unit such that anionic membranes form the end membranes, i.e. are the membranes next to the electrode compartments. Secondly, the deposition at the electrodes can also be controlled by selecting a large enough electrode rinse flow at a controlled pH to minimize the concentration of manganese and zinc. Thirdly, the amount of the deposits, especially of zinc, can also be controlled by adding small amounts of a soluble form of at least one element chosen from the group consisting of antimony and cobalt, the use of both being particularly advantageous. Additions of up to 100 mg Sb/L of rinse solution and/or up to 100 mg Co/L of rinse solution may be used. The preferred amounts are in the range of 2 to 10 mg Sb/L and 2 to 5 mg Co/L, at which levels of addition only a small amount of zinc is deposited. Lastly, the depositions, especially of zinc, can be controlled by using a cathode made of a suitable material to promote the evolution of hydrogen over zinc deposition. For example, a cathode material of platinum coated titanium may be advantageously employed. Any one of the above described means may be used alone or in combination with one or more of the other means to control the deposition at the electrodes. The cathode and the anode compartments are rinsed with circulating rinse solutions. For the sake of simplicity, the rinse solutions are a common rinse solution circulated to both the electrode compartments. The rinse solution may be chosen from water, dilute sulphuric acid and sodium sulphate maintained at a pH in the range of 0 to 4. the solution is preferably an acidified solution of sodium sulphate. A suitable rinse solution contains sodium sulphate in a concentration in the range of 0.1 to 1.0 M with or without added cobalt and antimony and is maintained at a pH at values in the range of 2 to 3, values in the higher end of the range being preferred for more efficient fluoride removal. The rinse solution is circulated at a rate sufficient to give a differential pressure across the membranes of less than 150 kPa, preferably less than 50 kPa. A portion of the rinse solution may be removed from circulation and be replaced with a substantially equal portion of fresh solution so that the zinc concentration in the rinse solution is maintained at about 150 mg/L or less. During electrodialysis, the monovalent cations and anions in the feed solution pass from the diluate cells to the concentrate cells through the monovalent permselective cationic and anionic membranes respectively, leaving substantially all multivalent cations and anions in the diluate cells. The gases evolved at the electrodes are carried from the cathode and anode compartments in the rinse solution. The electrodialysis unit may be operated with solution temperatures in the range of from just above the freezing temperature of the solution to as high as 60°C, i.e. from 0 to 60°C, preferably 20 to 50°C. The method is conducted with an electrolyte feed solution having a value of the apparent pH that must be less than about 5.5 At values above about 5.5, precipitation of zinc as hydroxide or basic zinc sulphate can occur. At values of the pH below about 2, bisulfate ions are formed and transferred. Consequently, the pH of the electrolyte feed is preferably in the range of from 2 to 5.5. We have also found that the removal of fluorine is especially sensitive to the pH due to the formation of hydrogen fluoride at pH below about 3.5. The pH of the diluate and concentrate streams is, therefore preferably at a value of not less than about 2 and, to enhance fluoride removal, most preferably at a value in the range of from 3.5 to 5.5. The flow rate of solutions through the concentrate and diluate cells should be such that the linear velocity is sufficient to obtain turbulent flow. The flows of solutions through the concentrate and diluate cells and the anode and cathode compartments should be substantially balanced in order to maintain a differential pressure across the membranes that does not exceed about 150 kPa and is preferably in the range of from 0 to 50 kPa. Feed rates to the electrodialysis unit may be selected in the range of 2 to 40 L/h.m² per membrane pair, the selected value being dependent on the impurity concentrations in the electrolyte and the value of the current density. The process can be oepratd with a current applied to the electrodes such that the equivalent membrane current density (applied current per effective membrane surface area) is in the range of 10 to 500 A/m². Below 10 A/m², the ionic transfer rate is too low, while above 500 A/m² the rate of replenishing monovalent ions at the membrane diffusion layer is too low, with resulting water splitting and/or loss of permselectivity. Water splitting and permselectivity loss are substantially obviated when operating with current densities in the preferred range of 50 to 300 A/m². Although electrodialysis may be effective in one stage to reduce concentrations of monovalent ions to the desired low concentrations, it may be desirable to have more than one stage of electrodialysis. In more than one stage, the stages are preferably connected in series, diluate withdrawn from one stage being fed to the diluate cells of a subsequent stage whereby concentrations of monovalent ions may be further reduced. If desired, the concentrate may be further concentrated by electrodialysis. Concentrate withdrawn from concentrate cells from the first stage electro­ dialysis is fed to the diluate cells of a second stage. Such a step may be advantageous to reduce loss of zinc with the concentrate, as concentrate is usually discarded as an effluent, after treatment. Diluate from such a second electrodialysis of concentrate may be returned as feed to the first stage electrodialysis. If needed, the membranes may be cleaned periodically to remove any deposits such as of calcium sulphate or fluoride, or magnesium fluoride. The membranes may be cleaned with a suitable acid solution such as, for example, a 15% solution of acetic acid or a 2 M hydrochloric acid followed by adequate rinsing with water. The electrodes may be cleaned with dilute sulphuric acid. The invention will now be illustrated by means of the following non-limitative examples. Example 1 This example illustrates the removal of monovalent ions from zinc sulphate electrolyte by electrodialysis. the electrodialysis unit contained a number of alternating Selemion TM ASV anion permselective membranes and Selemion TM CSV cation permselective membranes. The membranes were arranged conventionally such that an anion permselective membrane was next to the anode compartment, and a cation permselective membrane was next to the cathode compartment, both end cells (i.e. cells next to electrode compartments) being diluate cells. An anode plate made of platinum-plated titanium and a cathode plate of stainless steel (SUS 304) were used in the anode and cathode compartment, respectively. A zinc sulphate electrolyte solution containing 150 mg/L Cl⁻, 50 mg/L F⁻ and 12 mg/L Tl⁺ was continuously fed to a recirculated diluate stream at 19.5 L/h.m² of effective membrane pair area, i.e. cell. The diluate stream was recirculated through the diluate cells at a linear velocity of 5 cm/s.. Water, to which a small amount of electrolyte was added to improve electrical conductivity, was recirculated through the concentrate cells at a linear velocity of 5 cm/s. A 0.5 M sodium sulphate solution, adjusted to pH 2 with sulphuric acid was fed at 116 L/h.m² per electrode pair to the electrode compartments to form the electrode rinse stream. The electrode rinse stream was recirculated through the electrode compartments at a rate sufficient to give a differential pressure of less than 10 kPa between it and the diluate and concentrate streams. The differential pressure between the diluate and concentrate streams was measured to be 3 kPa. A direct current was passed between the electrodes at a current density of 174 A/m². Streams of the diluate, the concentrate and the electrode rinse solution were withdrawn. A net water transfer of 1.5 L/h.m² per cell occurred from the diluate to the concentrate stream. The test was continued for 7 hours. The flowrates, pH and temperatures, and the result of Cl⁻, F⁻ and Tl⁺ transfer after the 7 hour period are given in Table 1. Example 2 In order to further improve fluoride removal, the experiment of Example 1 was repeated but with a feed rate of 9.7 L/h.m² and an electrode rinse solution maintained at a pH of 2.8 and at a flow rate of 70 L/h.m². The increased pH of the rinse solution resulted in a correspondingly higher pH of the diluate and concentrate streams of 3.9 and 3.4, respectively. The fluoride removal improved to 31%. Thus, fluoride removal can be improved by increasing the pH of the diluate and concentrate recirculating streams to a value of at least about 3.5. Example 3 A number of tests was carried out in an effort to reduce the amounts of zinc and manganese that deposit on the electrodes. Using the equipment and conditions of previous examples, zinc and manganese concentrations in the electrode rinse solution were found to increase steadily with time. The tests of this example were carried out with various compositions and flow rates of the sodium sulphate rinse solution. A soluble form of cobalt, i.e. cobalt sulphate, and of antimony, i.e. potassium antimony tartrate, were added in varying amounts to the rinse solution. Rinse solution was circulated through the electrode compartments at a rate sufficient to maintain the differential pressure across the membranes at about 10 kPa. A portion of the circulating solution was withdrawn and replaced with fresh solution. At the end of each test, i.e. after 72 h, the zinc and manganese contents of the removed solution were determined. The current density, strength and pH of and additions to the rinse solution, the feed rate of fresh solution, and the zinc and manganese concentrations in removed rinse solution are given in Table II. In tests No. 2 and 3 the amount of zinc deposited on the cathode was 2050 mg and 560 mg, respectively, while little or no zinc deposited in tests 4 and 5. The amount of manganese was visually judged as decreasing from the first to the last test. It follows from these tests that the transfer of zinc and manganese to the electrode compartments can be reduced by using a high electrode rinse flow and/or the addition of a small amount of antimony and cobalt to the rinse solution. The combination of the use of a relatively large feed rate of fresh rinse solution and amounts of cobalt and antimony of less than 100 mg/L and as small as 10 and 5 mg/L respectively, gave excellent results. Example 4 This example illustrates that electrode deposits can be significantly further reduced by arranging the membranes such that anion permselective membranes are adjacent the electrode compartment and by using a cathode of a material that promotes evolution of hydrogen over zinc deposition. Using the electrodialysis unit used in previous examples, Selemion TM ASR anion and Selemion TM CMR (surface treated) cation permselective membranes were alternately arranged such that anion permselective membranes were next to both cathode and anode compartments and the cells adjacent the electrode compartments were diluate cells. The anode was made of platinum-coated titanium. The cathode in tests 1 and 2 was made of stainless steel (SUS 304) and in test 3 of platinum-coated titanium. The rinse solution in tests 1 and 3 was 0.1 M Na₂SO₄ at pH 2.5 and in test 2 0.1 M Na₂SO₄ with an added amount of 2 mg/L Co and 2 mg/L Sb at pH 2.5. Each test was continued for 72 hours. The current denisty, rinse solution flow rate, the range of zinc and manganese concentrations in the rinse solution of the 72 h period, and the weight of electrode deposits collected over the same period are given in Table III. It is noted that in other tests it had been determined that the Selemion TM ASR and CMR membranes yield results very much the same as the ASV and CSV membranes. Example 5 Test No. 3 of Example 4 was repeated using the same equipment and conditions, but after completion of the test the electrode compartments were washed for 80 minutes with a circulating solution of 0.5 M sulphuric acid. The resulting wash solution contained 210 mg zinc. The result shows that the electrode compartments can be effectively cleaned in situ. Example 6 This example illustrates the electrolyte with very high halide concentrations can be successfully treated. The electrodialysis unit as used in Example 4 was used. Test conditions and results are given in Tables IV and V. The preciptiate was found to consist mostly of sellaite (MgF₂). Precipitate accounts for the lower than expected fluoride concentration in the concentrates streams. Example 7 This example illustrates that losses of zinc from the electrolyte to the concentrate can be reduced by conducting electrodialysis at low current densities. Using the electrodialysis unit described in Example 4, electrolyte was fed at 13.6 L/h.m² per membrane pair. The current density was 50 A/m². the results are given in Table VI. Water transfer to concentrate was 0.2 L/h.m² per membrane pair. The feed stream contained 149 g/L Zn, the zinc transfer rate to the concentrate stream was 0.37 moles/h.m² per membrane pair. Using the same electrolyte, a comparative test was made at 100 A/m². Although halide removal increased to 87% Cl⁻ and 56% F⁻, the water transfer also increased to 0.6 L/h.m², while the rate of zinc transfer increased to 1 mole/h.m² per membrane pair. Example 8 This example illustrates that zinc losses to a final concentrate, which is disposed of as an effluent after treatment, can be reduced by subjecting the concentrate to a retreatment. A primary concentrate stream composite from various tests after standing (and sellaite precipitation) and having a pH of 3.4 was treated in the electrodialysis unit arranged as in Example 4. Electrodialysis was conducted at 150 A/m² with an electrolyte feed rate of 12.8 L/h.m² per membrane pair. The results are given in Table VII. Water transfer from dilute to concentrate stream was 0.92 L/h.m² per membrane pair. Example 9 This example illustrates the transfer of various elements in zinc sulphate electrolyte during electro­ dialysis. A typical electrolyte may contain Zn, Mg, Mn, Ca, Na, K, Cl, F, Tl, etc., and is basically a sulphate system. The distribution of elements during electro­ dialysis is illustrated by the following tests summarized in Table VIII, with stream compositions and pH values diven in Table IX. Membranes used in all three tests were Neosepta TM CMS & ACS. It follows from the results that monovalent ions (Na⁺, K⁺, Tl⁺, Cl⁻ and F⁻) in the feed solutions were preferentially transported into the concentrate stream, and hence effecting their removal from the feed electrolyte, resulting in purified electrolyte.

Claims: 1. A method for the purification of zinc sulfate electrolyte containing concentrations of monovalent cations including at least one cation chosen from the group consisting of thallium, sodium and potassium and monovalent anions including at least one anion chosen from the group consisting of chloride and fluoride by electrodialysis, characterized in that the method comprises the steps of feeding zinc sulfate electrolyte to diluate cells of an electrodialysis unit comprising a multiplicity of alternating monovalent cation permselective exchange membranes and monovalent anion permselective exchange membranes, said membranes defining alternating diluate and concentrate cells, an anode compartment and a cathode compartment, an anode positioned in the anode compartment and a cathode positioned in the cathode compartment; rinsing said anode compartment and said cathode compartment with circulating rinse solutions; applying an electrical current between the anode and the cathode at a value such that the value of the corresponding current density is in the range of 10 to 500 A/m²; maintaining the temperature in the unit in the range of 0 to 60°C; feeding electrolyte at a pH having a value of less than about 5.5; passing flows of solutions through the diluate and concentrate cells at a linear velocity sufficient to maintain turbulent flow in said cells; withdrawing a diluate from said diluate cells as the purified zinc sulfate electrolyte with reduced concentrations of monovalent cations and monovalent anions. 2. A method as claimed in claim 1, characterized in that a quantity of a receiving solution is fed to the concentrate cells when the net water transfer rate to the concentrate cell in the electrodialysis is less than the withdrawal rate of concentrate from the concentrate cells, said receiving solution being chosen from water, dilute sulfuric acid and dilute sodium sulfate solution. 3. A method as claimed in Claim 1 or 2, wherein deposition occurs on the electrodes, characterized in that said deposition is controlled at a minimum by at least one of a number of means chosen from arranging said membranes in the electrodialysis unit such that monovalent anionic permselective exchange membranes form the end membranes next to the electrode compartments; selecting a large flow of said rinse solutions; making said cathode of a suitable material that promotes the evolution of hydrogen over zinc deposition; and adding to said rinse solutions a soluble form of antimony in an amount of up to 100, preferably 2 to 10, mg Sb/L of rinse solutions and a soluble form of cobalt in an amount of up to 100, peferably 2 to 5, mg Co/L of rinse solutions. 4. A method as claimed in claim 1, 2 or 3, characterized in that a portion of said rinse solutions is removed from circulation and is replaced with a substantially equal portion of fresh solution so that the concentration of zinc in said rinse solutions is maintained at less than about 150 mg/L. 5. A method as claimed in any preceding claim, characterized in that said electrodialysis is carried out in more than one stage by feeding diluate withdrawn from said diluate cells in one stage to diluate cells of a subsequent stage whereby concentrations of monovalent ions are further reduced. 6. A method as claimed in any preceding claim, characterized in that said electrodialysis is carried out in two stages by feeding concentrate withdrawn from said concentrate cells in one stage to diluate cells of a second stage whereby loss of zinc in concentrate is reduced. 7. A method as claimed in any preceding claim, characterized in that said membranes are cleaned periodically with a solution chosen from the group consisting of a 15% solution of acetic acid and 2 M hydrochloric acid followed by adequate rinsing of said membranes with water. 8. A method as claimed in any preceding claim, characterized that at least a portion of the diluate removed from the diluate cells is recycled to the diluate cells and at least a portion of the concentrate withdrawn from concentrate cells is recycled to the concentrate cells. 9. A method as claimed in any preceding claim, characterized in that zinc sulfate electrolyte is fed to said diluate cells at rates in the range of 2 to 40 L/h.m² per membrane pair; said membranes have a membrane matrix of a styrene di-vinyl benzene copolymer and have active groups in an amount in the range of about 3 to 4 milli-equivalents per gram of dry resin, the active groups of the monovalent cation permselective exchange membranes being sulfonic acid radicals and the active groups of the monovalent anion permselective membranes being quaternary ammonium groups preferably derived from trimethylamine; said circulating rinse solutions are a common circulating rinse solution of sodium sulfate containing sodium sulfate in a concentration in the range of 0.1 to 1.0 M, said common solution being maintained at a value of the pH in the range of 0 to 4, preferably 2 to 3; said electrical current is applied such that the value of the corresponding current density is in the range of 50 to 300 A/m²; the temperature in the unit is maintained in the range of 20 to 50°C; electrolyte is fed at a pH having a value in the range of 2 to 5.5 preferably 3.5 to 5.5; said flows of solutions are passed through the diluate and concentrate cells and said rinse solution is circulated through said anode compartment and said cathode compartment at flow rates such that the differential pressure across the membranes is less than 150, preferably less than 50 kPa. 10. A method as claimed in any preceding claim characterized in that said monovalent cation permselective exchange membranes in the electrodialysis unit are replaced with cation exchange membranes which have a membrane matrix of a styrene d-vinyl benzene copolymer and active groups of sulfonic acid radicals in an amount in the range of about 3 to 5 milli­ equivalents per gram of dry resin, and purified zinc sulfate electrolyte with reduced concentrations of monovalent anions is recovered.

Inventors: BALL, DONALD L, BOATENG, DANIEL A D
Applicants: COMINCO LTD.
Application year: 1987
Main classification: B01D61
IPC codes: C25C1, B01D61, C01G9, B01D65