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HYDROMETALLURGY
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HYDROMETALLURGY
Practice
Volume 2
MICHAEL NICOL
Murdoch University, Murdoch, WA, Australia
with contributions by
NICHOLAS WELHAM
GAMINI SENANAYAKE
Elsevier
Radarweg 29, PO Box 211, 1000 AE Amsterdam, Netherlands
The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom
50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States
This book and the individual contributions contained in it are protected under
copyright by the Publisher (other than as may be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research
and experience broaden our understanding, changes in research methods,
professional practices, or medical treatment may become necessary.
Practitioners and researchers must always rely on their own experience and
knowledge in evaluating and using any information, methods, compounds, or
experiments described herein. In using such information or methods they should be
mindful of their own safety and the safety of others, including parties for whom they
have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or
editors, assume any liability for any injury and/or damage to persons or property as a
matter of products liability, negligence or otherwise, or from any use or operation of
any methods, products, instructions, or ideas contained in the material herein.
ISBN: 978-0-323-99214-5
1 Leaching practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Leaching methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Typical leaching processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Batch leaching kinetics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Continuous leachingdmicro- and macrofluids . . . . . . . . . . . . . . . . . . 6
1.5 Counter-current leaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.6 Bacterial oxidation and leaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7 Pressure leaching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.8 Heap leaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.9 In situ leaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.10 Leaching of gold and silver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.11 Alternative lixiviants for gold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.12 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Problemsdleaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Case study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Further reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2 Solideliquid separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2 Sedimentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3 Thickeners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.4 Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Further reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Case study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
vi Contents
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Leaching practice
1
The chemistry of processes aimed at the dissolution of
valuable metals from various feed materials was covered in
Chapter 6 in Volume 1. In this chapter, the various methods
employed to carry out the leaching reactions will be outlined
The choice of a particular leach process and the equipment to
be used depends on the performance that can be achieved by the
various options. The main factors to be taken into account in
assessing leach performance are the following.
• Degree of dissolution of desired species.
• Selectivity of leaching process with respect to the desired
species.
• Leaching time required to achieve the desired extraction.
• Operating cost (lixiviants, power).
• Capital cost.
There is generally an economic optimum that determines the
most appropriate strategy for leaching. Thus, for the leaching of
gold ores, the objective should be to maximize extraction given
that operating costs are generally not high relative to the value
of the product. On the other hand, in the case of the leaching
of low-grade copper ores, the operating costs are the most impor-
tant consideration and heap leaching is the only viable option.
Even in this case, high acid consumption can rule out heap leach-
ing for some ores.
Hydrometallurgy. https://doi.org/10.1016/B978-0-323-99214-5.00006-1
Copyright © 2022 Elsevier Inc. All rights reserved. 1
2 Chapter 1 Leaching practice
Vat leaching: Crushed ore fills a large vat that is then filled with
lixiviant and left to leach. A batch process that is not very
common.
Chapter 1 Leaching practice 3
Ore
Lix. Lix.
Tank Treat
Lix.
Tank
Figure 1.2 Schematic to distinguish between microfluid (left) and macrofluid (right).
8 Chapter 1 Leaching practice
0.8
0.6
θ)
E(θ
0.4
0.2
0
0 1 2 3
θ
Figure 1.3 Residence time distribution for a single CSTR.
Reactors, N 1 2 3 5 10
Mean t/s Range t/s Fraction Fraction Fraction Fraction Fraction
0.1 0e0.2 0.1814 0.0596 0.0248 0.0046 0.0001
0.3 0.2e0.4 0.1485 0.1286 0.0967 0.0499 0.0094
0.5 0.4e0.6 0.1216 0.1457 0.1480 0.1314 0.0773
0.7 0.6e0.8 0.0996 0.1375 0.1604 0.1853 0.1979
0.9 0.8e1.0 0.0815 0.1189 0.1463 0.1876 0.2563
1.1 1.0e1.2 0.0667 0.0976 0.1204 0.1552 0.2148
1.3 1.2e1.4 0.0546 0.0774 0.0926 0.1122 0.1334
1.5 1.4e1.6 0.0447 0.0599 0.0678 0.0736 0.0667
1.7 1.6e1.8 0.0366 0.0456 0.0479 0.0449 0.0283
1.9 1.8e2.0 0.0300 0.0342 0.0329 0.0259 0.0106
2.1 2.0e2.2 0.0246 0.0253 0.0221 0.0142 0.0036
2.3 2.2e2.4 0.0201 0.0186 0.0145 0.0076 0.0011
2.5 2.4e2.6 0.0165 0.0136 0.0094 0.0039 0.0003
2.7 2.6e2.8 0.0135 0.0098 0.0060 0.0020 0.0001
2.9 2.8e3.0 0.0110 0.0054 0.0012 0.0003 0.0000
>3.0 0.0490 0.0224 0.0089 0.0015 0.0000
Figure 1.5 Distribution of particle sizes and shapes in a gold (blue (dark gray in print)) concentrate. The green
particles (light gray in print) are pyrite.
Fraction
Within
Each
Class
enough, settle in the bottom of the tank while the fine particles
will probably have a shorter mean residence time. This effect
will, in part, act to compensate for the normal RTD in that we
want the larger particles to have a longer residence time. For
this reason, the complications caused by the RTD effect are often
ignored.
In a real agitated tank reactor, however, there is often a degree
of short-circuiting of the pulp due to inefficient blending of the
incoming pulp with the contents of the tank coupled to inappro-
priate positioning of the feed and exit points. The settling of
larger particles can also often result in a significant fraction of
12 Chapter 1 Leaching practice
the tank volume being unavailable for reaction. This is, as ex-
pected, more prevalent in the first tank in a series and the peri-
odic use of tracer tests to establish the active volume of the
tank will enable this problem to be highlighted.
It is apparent that a full treatment of the kinetics of leaching
of a real ore or concentrate will require information on the parti-
cle size distribution. Given all the previously mentioned compli-
cations when dealing with real leach systems, the added
complexity of the population balance models cannot generally
be justified. The Appendix outlines the application of conven-
tional CSTR theory for the treatment of leaching reactions
bearing in mind the previously mentioned problems in particu-
late systems.
Calcine
Spent L
Electrolyte SLL
L
SLLL
L
3rd Stage Leach, 80oC, 50 g/L acid SLL
S
LLL Residues
Figure 1.8 Bacteria (yellow (light gray in print)) associated with sulfide minerals.
Oxygen
S, Heat of Reaction demand H2SO4
Mineral % kJ/kg kJ (kg/S) kg (kg/S) Demand kg /kg
Pyrrhotite 36.4 11,373 31,245 2.25 0.558
FeS
Arsenopyrite 19.6 9415 48,036 3.51 0.301
FeAsS
Pyrite 53.3 12,884 24,173 1.88 0.408
FeS2
Chalcopyrite 34.9 9593 27,505 2.13
CuFeS2
Chalcocite 20.1 6201 30,811 2.50
Cu2S
Pentlandite 33.2 10,174 30,644 2.20
(Ni,Fe)9S8
Dolomite 0 219 e e 0.979
Ca(Mg) (CO3)2
Chapter 1 Leaching practice 17
• Residence time
• Corrosion resistance of the materials of construction given
acidic conditions.
10 100
9 90
8 80
Au recovery, %
6 60
5 50
4 40
3 30
2 S oxidised 20
1 10
Au
0 0
0 50 100
Feedrate, t/day
Figure 1.9 Typical biooxidation operating characteristics showing the effect of concentrate feed rate on the extent
of sulfide sulfur oxidized and gold recovered. Also shown are operating lines for 60% (____) and 85% (..)
oxidation.
diagram that shows two “operating” lines at 60% and 85% oxida-
tion. Note the effect of feed rate on the rate of oxidation of the sul-
fide and on the subsequent recovery of gold by cyanidation. Why
does the rate of sulfide oxidation decrease at a feed rate of greater
than about 55 t d1?
In both bioleaching (or biooxidation) and pressure leaching
processes, the rate-determining step can be the transfer of oxy-
gen from the gas phase to the liquid phase, and, as outlined in
Chapter 5 in Volume 1, this flux(j) of oxygen can be described
by the equation
j ¼ KL ðc co Þ (1.13)