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By Waraporn Piyawit

Grinding sludge from the sintered neodymium-iron-boron (NdFeB) magnets production process was enriched with critical rare earth elements (neodymium, dysprosium and praseodymium), which can be up to 30% in the magnets. The demand of NdFeB magnets are simultaneously growing. Therefore, rare earths recovered from waste residue would reduce the demand of rare earth elements from primary sources. In this study, the feasibility of recycling rare earths through a hydrometallurgical process was investigated. The selective leaching of Nd from grinding sludge can successfully raise the rare earths concentration to 70%. The necessity of an oxidation pretreatment to improve the selectivity between Nd and Fe will be described.

By Mogi G, Akaike A, Yamaguchi U

A new algorithm has been investigated for three-dimensional open pit designs to improve the dynamic cone approach which utilises the dynamic programming technique. The conventional dynamic cone method was improved by introducing examination processes: 1. whether any negative blocks are included in a unit cone or not; and 2. whether it is possible or not to leave the negative blocks unmined in the unit cone without disturbing the geometric condition imposed on the slope angle of the cone. The newly developed algorithm was applied to a large-scale open pit copper mine in a planning stage and the results have been compared with those obtained by the conventional methods.

Jan 1, 1995

By Kazutoshi Haga, Batnasan Altansukh, Atsushi Shibayama

In this study, the dissolution behavior of copper and arsenic from five different copper concentrates containing 21-34.7 %wt. of Cu, 1.3-7.3 %wt. of As and 15.6-27.5 %wt. of Fe were investigated under high pressure oxidative leaching conditions. Leaching experiments were conducted using different leaching reagents such as ferric sulfate, sodium chloride, deionized water, sulfuric acid and ferric sulfate-sodium chloride mixture in order to compare the effectiveness of each on the dissolution of copper and arsenic from copper concentrates. The effects of ferric sulfate (0.1-1 mol/L), sodium chloride (0.1-0.5 mol/L) and leaching temperature (100-180C) were investigated under 1 MPa autoclave pressure , particle size >45 m, pulp density of 100 g/L, stirring speed of 750 rpm and leaching time of 60 min. Results showed that the most effective leaching reagents for the dissolution of copper are 0.34 M NaCl and a mixture of 0.1 M Fe2(SO4)3 - 0.34 M NaCl, in which As extraction did not exceed 7%. The copper concentration in the pregnant leach solution obtained after leaching using 0.1 M Fe2(SO4)3 - 0.34 M NaCl was 13-30 g/L, while the concentration of As and Fe were in a range between 0.3-1 g/L and 0.2-10 g/L at 160C. INTRODUCTION Copper sulfide minerals, such as chalcopyrite (CuFeS2), chalcocite (Cu2S) and covellite (CuS) are used for the production of copper in mining and metallurgical industries worldwide. The conventional pyrometallurgical processing followed by electrorefining is a common process for the production of high purity copper (Moskalyk, & Alfantazi, 2003; Padilla, Aracena, & Ruiz, 2012). However, the degradation of copper content and an increase in the amount of metal impurities, especially arsenic (As), antimony (Sb) and bismuth (Bi) in copper concentrates cause serious problems to the production of copper and environmental pollution (Basha, Selvi, Ramasamy, & Chellammal, 2008; Long, Peng, & Bradshaw, 2012). Hydrometallurgical processes are used to recover metals from refractory ores, concentrates and tailings by leaching (Long, Peng, & Bradshaw, 2012; Masloboev, Seleznev, Svetlov, & Makarov, 2018). During the last decades, hydrometallurgical processing for the recovery of copper from enargite-bearing copper ores and concentrates has been extensively investigated due to its relatively more environmentally benign and less capital costs than the conventional pyrometallurgical processes (Long, Peng, & Bradshaw, 2012; Masloboev, Seleznev, Svetlov, & Makarov, 2018; Choubey, Lee, Kim, & Kim 2018). However, several issues facing the hydrometallurgical processing are incomplete extraction of copper associated with the coprecipitation of iron compounds, difficult stabilization of toxic impurities and production of a contaminated copper product (Dreisinger, 2003; Safarzadeh, Moats, & Miller, 2014). Hence, a number of studies have been conducted on the selective dissolution of copper from copper ores and concentrates or selective removal of arsenic leaving a clean copper residue using various leaching reagents or lixiviants (Safarzadeh, Moats, & Miller, 2014; Mihajlovic, Strbac, Zivkovic, Kovacevic, & Stehernic, 2007; Tongamp, Takasaki, & Shibayama, 2009). More extensive studies on the selective extraction of copper from enargite- bearing copper ores and concentrates are much needed to improve copper recovery.

Jan 1, 2019

By L. L. Godirilwe, and A. Shibayama, G. Danha, K. Haga, Y. Takasaki

Selective extraction through leaching of an amorphous slag obtained from a base metal smelter plant in Botswana is investigated in this paper, where the main objective is to optimise the experimental variables that would result in the maximum selective extraction of the three base metals (Ni, Cu and Co) from the slag waste. Mineralogical tests showed that the sample is composed mainly of fayalite (Fe2SiO4), with a total entrapped metal sulphides content of about 1.0 wt.% occurring as fine occlusions in the fayalite phase. In our experimental program, we compare the effectiveness of two common leaching techniques. In the first method, we use sulphuric acid to carry out atmospheric beaker leaching tests, and in the second method we use high pressure oxidative leaching. The effects of acid concentration, oxidant addition/oxygen partial pressure and pulp density on metal dissolution rate are examined. The optimal Ni, Cu, Co extractions of 80.5%, 81.9 and 98% respectively were obtained under high pressure oxidative leaching conditions (150 oC, 0.6 M H2SO4, 0.5 MPa O2), with substantially low dissolved Fe of 9.6%, the majority of which was removed as jarosite in the residue. Atmospheric beaker leaching yielded poor extractions of Ni below 40% when sulphuric acid combined with hydrogen peroxide (1.0 M and 0.6 M respectively, 65 oC) were used for leaching, while Fe, Cu and Co dissolutions were each about 80%. Therefore, using high pressure oxidative leaching provides a possibility to effectively extract Ni, Cu and Co while producing an environmentally benign residue, thus alleviating the current adverse environmental issues associated with the abandoned smelter slag. Keywords: Slag, amorphous, fayalite, atmospheric beaker leaching, high-pressure oxidative leaching, extraction

Jan 1, 2020

By M. Tanaka, H. Narita, K. Morisaku

"The selective separation of palladium (Pd), platinum (Pt), and rhodium (Rh) from a hydrochloric acid solution by solvent extraction was investigated using amide-type extractants, i.e., N,N,N’,N’-tetra-n-octyl-thiodiglycolamide (TDGA) and N-n-hexyl-bis(N-methyl-N-n-octyl-ethylamide) amine (BisAA). The separation experiments employed two separation schemes: (1) extraction of Pd with TDGA and that of Rh and Pt with BisAA; and (2) extraction of Rh, Pd, and Pt with BisAA. Separation scheme 1 achieved the highly selective separation of each metal. For separation scheme 2, Rh can be recovered prior to Pd and Pt, despite having a lower selectivity for Pd/Pt than separation scheme 1. INTRODUCTIONThe recent increase in the use of platinum group metals (PGMs) in industry (especially auto catalysts containing palladium (Pd), platinum (Pt), and rhodium (Rh)) has lead to their increasing waste; therefore, improvements in the recovery techniques for PGM have received significant attention. In metal refineries, PGMs are mainly separated and purified by solvent extraction (Cox, 2004). The extraction process used in INCO’s Acton precious metal refinery is one of the most famous commercial processes and is utilized worldwide. In this process, silver is first removed as a residue (AgCl), and then gold, Pd and Pt are extracted from hydrochloric acid (HCl) solutions using dibutylcarbitol (DBC), dialkylsulfide (DAS), and tri-n-butylphosphate (TBP), respectively. Finally, Rh remains in the raffinate (Barns & Edwards, 1982).The development of a successful solvent extraction process depends on the choice of the appropriate extractants. We have studied the extraction of PGM using N,N-disubstituted amide compounds (Narita, Tanaka, Morisaku, & Abe, 2004; Narita, Tanaka, Morisaku, & Tamura, 2006; Narita, Tanaka, & Morisaku, 2008a, 2008b). They are relatively stable against acids, and their metal extractability can be improved by changing the side chain length and/or introducing additional donor atoms like sulfur and nitrogen. We have recently found that thiodiglycolamide and an amide-containing tertiary amine have good extractabilities for Pd and Rh, respectively."

Jan 1, 2012

By Augusto Viana Leandro Teixeira

Rare Earth Elements (REE) are fundamental for modern life products and green technologies. Supply constraints and the price peak of 2011 boosted intensive research for alternatives for processing and separation. Complex monazite- type, rare earth ores usually contain high acid consumption impurities, such as iron and aluminum, and radioactive thorium in their composition. These impurities are not removed by conventional concentration processes due to fine, micro-level association between the REE carrying minerals and the gangue minerals. This work presents a selective process route for REE extraction from iron-rich, monazite ores. The process involves sulfation by addition of concentrated sulfuric acid and pyrohydrolysis at temperatures of approximately 700–750 °C. Experimental results show REE extraction higher than 70% and low iron (below 5%) and thorium extraction (below 10%). A method based on thermogravimetric analyses was shown to be adequate to predict the behavior of a given ore sample in the sulfationselective pyrolysis-leaching process.

By Leandro Augusto Viana Teixeira, Angela Avelar, Ruberlan Gomes Silva, Virginia S. T. Ciminelli, Daniel Majuste

Rare earth elements are essential for modern life products and green technologies. Recent supply constraints have boosted the development of rare earth projects after the price peak of 2011. The feasibility of a project depends on the definition of a processing route, which in turn depends primarily on the rare earth mineral, with monazite and bastnaesite representing the two most relevant minerals. Monazite-type ores usually contain high acid consumption impurities, such as iron, aluminum, calcium, magnesium and phosphates, and may also contain prohibitive levels of radioactive thorium in its composition. Based on thermodynamic analysis, the present work discusses the fundamentals of a selective process route for rare earth extraction from monazite ores with high iron content. This process involves sulfation by means of concentrated sulfuric acid and roasting at a high temperature. The route yields high rare earth extraction with low iron and thorium extraction and low acid consumption. Rare earth extractions as high as 80 percent were achieved, while iron and thorium extractions were lower than 1 percent, and acid consumption was lower than 0.34 kg of sulfuric acid per kg of ore. The operational window was compared to the one predicted by thermodynamic modeling, with 700 °C representing the optimal roasting temperature.

By Leandro Augusto Viana Teixeira, Angela Avelar, Ruberlan Gomes Silva, Virginia S. T. Ciminelli, Daniel Majuste

Rare earth elements are essential for modern life products and green technologies. Recent supply constraints have boosted the development of rare earth projects after the price peak of 2011. The feasibility of a project depends on the definition of a processing route, which in turn depends primarily on the rare earth mineral, with monazite and bastnaesite representing the two most relevant minerals. Monazite-type ores usually contain high acid consumption impurities, such as iron, aluminum, calcium, magnesium, and phosphates, and may also contain prohibitive levels of radioactive thorium in its composition. This work presents a thermodynamic analysis of a monazite system and discusses the fundamentals of a selective process route for rare earth extraction from monazite ores with high iron content. This process involves sulfation by means of concentrated sulfuric acid and roasting at a high temperature. The route yields high rare earth extraction with low iron and thorium extractions and low acid consumption. Rare earth extractions as high as 80% were achieved, while iron and thorium extractions were lower than 1%, and acid consumption was lower than 0.34 kg of sulfuric acid per kg of ore. The operational window was compared to the one predicted by thermodynamic modeling, with 700 °C representing the optimal roasting temperature

By M. D. Stephens

A new, one-step process for extracting titanium from titaniferrous materials has been demonstrated. In the process, depleted uranium tetrafluoride (DUF 4), a solid, is mixed with ilmenite (FeTi03) and heated to 900°C. Titanium is extracted in the vapor phase as titanium tetrafluoride (TiF4) and the DUF4 is converted to uranium-iron oxide. The process has been found to selectively fluorinate the titanium in ilmenite and is capable of producing high purity TiF 4 with very low iron content. TiF 4 can be collected by condensation or through reaction with a fluoride salt such as NH4F, KF, or NaF. The TiF4 produced from the process can be used to make titanium metal, titanium oxide, or fluorotitanate compounds. Since the fluorination process is highly selective for titanium, it avoids many of the separations and waste issues common to other titanium extraction processes.

Jan 1, 2001

By VIVEK KASHYAP, PATRICK TAYLOR

Zinc ferrite is the major phase component present in zinc refinery residue (ZRR) and electric arc furnace dust (EAFD). Up to 71 percent zinc ferrite has been reported to be present in ZRR, and in most studies zinc ferrite has been deemed the major phase in EAFD. In 2010, the global annual production of EAFD was 3.7 Mt, with 15.20 kg of EAFD generated per ton of recycled steel [1]. The generations of ZRR and EAFD have been growing over time, requiring a greener approach for the reutilization and extraction of valuable elements. ZRR can be a potential source of zinc, as its zinc content is as high as 30 percent [2,3]. The presence of zinc ferrite makes the extraction of zinc difficult because zinc ferrite is refractory to leaching, and direct leaching is inefficient. The Waelz process is currently employed to extract zinc from EAFD and other metallurgical wastes. The Waelz process operates in the temperature range of 1,100 to 1,500 °C and uses coke as reductant. This study explores a carbon-free and relatively low-temperature process for the selective extraction of zinc from pure zinc ferrite.

By VIVEK KASHYAP, PATRICK TAYLOR

The presence of iron in sphalerite induces the formation of zinc ferrite (ZF) during roasting. Zinc refinery residues (ZRR) and electric arc furnace dust (EAFD) contain a significant amount of zinc ferrite and are difficult to treat. According to the literature, up to 71% ZF has been found to be present in ZRR. The dissolution of zinc ferrite is inefficient even in aqua regia. The Waelz process is an existing process to recover zinc from electric arc furnace dust by reduction using carbon monoxide followed by the volatilization of zinc. In this study, zinc was selectively extracted from zinc ferrite by partial reduction of zinc ferrite at relatively low temperature followed by leaching in dilute sulfuric acid (20 g/L). Pure zinc ferrite samples were partially reduced to zinc oxide and magnetite by using H2 gas as a reductant. The presence of magnetite and zinc oxide was confirmed by X-ray diffraction (XRD) technique. A maximum of 95%zinc extraction was achieved after leaching with sulfuric acid on the reacted samples. The paper also discusses the effect of time, temperature, and concentration of H2 in the reducing gas on the extraction of zinc and iron from ZF.

Sep 16, 2020

By S. Mathur, Pradip

Polyacrylic acid (PAA) was evaluated as a selective flocculant for the dolomite-apatite system. PAA with a molecular weight (MW) of 4 million was found to flocculate both dolomite and apatite. However, the flocculation behaviors of dolomite and apatite were significantly different with 450,000 MW PAA, which was found to be the lowest molecular weight fraction capable of flocculation. In single-mineral tests with a dosage of 2 kg/t PAA, 90% of the dolomite and 35% of the apatite flocculated. Selectivity was achieved in mixed mineral tests. From a feed consisting of an 80:20 mixture of apatite and dolomite, respectively, a concentrate containing 90% apatite was obtained with a 70% recovery. The dolomite rejection was about 75%, which corresponds to a 2% MgO content in the concentrate.

Jan 1, 1997

By S. Mathur

Polyacrylic acid (P AA) was evaluated as a selective flocculant for dolomite-apatite system. P AA of 4 million MW was found to flocculate both dolomite and apatite. However, their flocculation behavior was significantly different with 450,000 MW PAA which was the lowest molecular weight fraction capable of flocculation. In single mineral tests, at a dosage of 2kg/t 90% of dolomite and 35% of apatite flocculated. Selectivity was achieved in mixed mineral tests where apatite of 90% grade at 70% recovery level was obtained in the concentrate from a feed consisting of 80:20 mixture of apatite and dolomite. The dolomite rejection was about 75% which corresponds to 1% MgO in the concentrate.

Jan 1, 1995

By Arthur F. Colombo

The selective flocculation, desliming and flotation process developed by the U.S. Department of the Interior, Bureau of Mines, as part of its goal of maintaining an adequate supply of minerals to meet national economic and strategic needs is described. The application of the selective flocculation and cationic flotation process to three oxidized taconites from the western Mesabi Range in Minnesota is discussed. Data from the operation of a 408-kilogram-per-hour (900 lb/hr) pilot plant employing reclaimed water are summarized for the three types of oxidized taconites.

Jan 1, 1980

By D. W. Frommer

In continuing its long range studies of methods of treating low-grade iron ores, the Bureau of Mines has developed a new selective flocculation, desliming, and flotation procedure that enables effective beneficiation of the finely disseminated ferruginous jaspers of the Marquette range, Mich. The process, developed on a bench scale and later confirmed in the 800-lb/hr pilot plant, comprises dispersion, selective flocculation, desliming to reject fine silica and clay, and flotation of silica from the remainder of minus 400-mesh pulps. Pilot plant flotation of two Marquette range ores, using the selective flocculation procedure on feeds containing 36 percent Fe, yielded iron recoveries of about 84 percent in concentrates containing 65 to 66 percent Fe and 4 to 5 percent silica. These results were metallurgically superior to those obtained when selective flocculation was not used. Also operating characteristics were better, and reagent costs were lower.

Jan 1, 1964

By K. Hanumantha Rao, A. Nayak, . K. S. Narasimhan, S. N. Mahapatra

Selective flocculation studies carried out with iron ore tailings generated at Kudremukh iron ore plant indicate that a concentrate containing 63% iron can be obtained from the tailings containing 34% iron with around 60% recovery. This opens up the possibility of recovering most of the iron lost in the tailings generated at 2 kt/h (2200 stph) while processing 22 Mt (24 million st) ore per year. This would mean that the productivity could increase by around 50%. In these studies, it has been established that caustic degraded tapioca starch is a most effective agent for selective flocculation. While potato starch after caustic degradation can also be used, neither the parent starch nor the amylopectin compound is as effective.

Jan 1, 1986

By B. A. Hancock

It is not at all surprising that causticized potato and potato derived amylopectin starch solutions performed much better than their parent starches. Some preparation is required to rupture the starch granules to effect the polymeric adsorption and interparticle bridging necessary for selective flocculation. In laboratory work comparing the deslime performance of causticized and autoclave cooked laboratory corn starch solution preparations, it was found that higher deslime weight rejections, with attendant proportionally greater iron unit losses, occurred with the causticized starch. These results may be specific to the ore involved but they do suggest that cooking and causticizing cause different starch granule rup- ture and/or starch breakdown, which have an effect on desliming response. I calculated from the data in the article that the slimes product grades were high - 24.3% and 20.3% Fe when 53.7% and 54.5% Fe concentrate products were obtained, respectively, in Table 4, and 21% Fe with a 62.6% Fe concentrate in Table 5 - using the natural tailings sample, which had a head of 34.3% Fe. It may be advisable for the authors to consider different starch preparations in future investigations. The combination of upgrading and selectivity results presented in Table 4 are not as good as the authors suggest. The authors' claim that a system has been developed to produce saleable concentrates from the Kudremukh tailings is quite disconcerting. There are many hurdles yet to be crossed before commercial application of selective flocculation becomes possible because differ- ences between the very small-scale laboratory tests conducted and commercial application are rather large. Among the many differences are varying circuit feed grades that will occur from use of tailings, the apparent face that much lower tailings grades will be encountered in practice (it is much easier to achieve a high concentrate grade with reasonable recoveries using 34.3% Fe tailings as in the study rather than 25.3% Fe tailings grades that the plant apparently averages), the hydraulic nature of the thickeners used in operations compared to the static system used in laboratory tests, the different size distributions that will be obtained from a plant closed grinding- classification circuit, and differences in water used in a plant operation and the laboratory. The authors wrote that it was necessary to overgrind to be sure that the coarse gangue would not settle with the iron oxide floccules. This situation is likely to be exaggerated in commercial operations where it is assumed cyclones would be used for classification. Because cyclone classification is greatly influenced by particle densities, there will probably be an even greater difference in size between the iron and gangue particles in the plant, which would make the gangue slightly coarser still in relation to the iron. This would make the selective flocculation-desliming separations using the procedure employed by the authors even more difficult and, using the dispersant system the authors employed, greater overgrinding would be required. To grind finer to minimize the coarse gangue in the flocculated iron oxides is quite inefficient and appears not to broach the problem. The actual problem appears to be insufficient dispersion of the ground pulp. In this situation, addition of a dispersant would likely be required to attain a sufficiently high pulp dispersion level to efficiently effect a selective flocculation-desliming separation. Although the very coarse particles would still have a tendency to settle with the floccules, it probably would be found unnecessary to overgrind as much as indicated. Use of an optimum combination of dispersant and pH modifying reagents may also significantly improve the selectivity of desliming. Additionally, although it is possible that sufficient dispersion may be obtained by pH control alone in some situations, it is quite probable that added dispersity was obtained in the reported work from using distilled water. It is research experience that distilled water enhances dispersion. In commercial operations it may not be expected that sufficient dispersion will be obtained by pH control alone, unless the water used in the process is by nature quite dispersive. Overall, a change in the Kudremukh tailings dispersant scheme appears necessary where a dispersant is used in conjunction with a pH modifying reagent. With this change, different dispersion-flocculation responses will result that would have to be further evaluated. Therefore, it is still an open question whether an efficient and effective selective floccula- tion separation using Kudremukh tailings may be obtained that will produce saleable concentrates.

Jan 1, 1987

By T. A. P. Sankar, S. Gundiah, Pradip, R. A. Kulkarni

Two modified polyacrylamide flocculants, namely polyacrylamide with glycolic acid functionality (PAMG), and a copolymer of acrylamide with N-acryloyl-[T]- aminobutyric acid (HPVP), were synthesized, characterised and evaluated for selective separation in apatite/quartz and apatite/dolomite/calcite systems, respectively. PAMG flocculant was found selective in the separation of tricalcium phosphate (TCP) from its mixtures with quartz at acidic to neutral pH range. The selectivity deteriorated at alkaline pH. In contrast, polyacrylic acid (PAA) flocculant was found most effective only in the alkaline pH range. HPVP flocculant (even though flocculating all three minerals namely apatite, dolomite and calcite) was observed to be quite selective for the separation of calcite from apatite-dolomite minerals in single mineral tests in the presence of sodium hexametaphosphate dispersant at neutral pH. There was, however, no selectivity observed during tests on synthetic mixtures. This loss in selectivity is attributed to the phenomenon of hetero-flocculation, as reported earlier, for separation in an apatite-dolomite system with polyethylene oxide.

Jan 1, 1993

By Y. H. Zhan

In beneficiation of phosphate ores it is common to use screening to produce the coarse "pebble" concentrate, and flotation to process the -1+0.1 mm size fraction. The -0.1 mm desliming product is treated as tailings. A new partially hydrophobic flocculant, P(MAAA) latex was developed to enhance flotation recovery of fine apatite particles through selective flocculation.

Jan 1, 2002

By Y. H. Zhan

A new P(MAAA) latex was developed and used in separation of ultrafine apatite from calcite and silica by means of selective flocculation. The latex was found to flocculate selectively apatite from apatite/calcite and apatite/silica mixtures in the presence of sodium tripolyphosphate and sodium silicate over a pH range from 9.1 to 9.4. The separation of apatite from calcite was more selective with sodium tripolyphosphate, while the results of the separation of apatite from silica were better when sodium silicate was used. In the apatite/calcite system, 90% apatite recoveries into a concentrate containing 34% P2O5 were possible in the presence of 4 mg/l of sodium tripolyphosphate at a latex dosage of 2.2 kg/t. In the apatite/silica system, 80% of apatite could be recovered into a concentrate containing 33% P2O5 in the presence of 20 mg/l of sodium silicate at a latex dosage of 1.1 kg/t. Deposition tests were used to study the interaction between the latex and the mineral surfaces. The results revealed that deposition density of the latex on apatite was higher than on calcite; the differences between the deposition onto these two minerals were higher at pH 9.2 than at 7.2. The results point to the stronger interaction between the latex and apatite surface when compared with the latex-calcite interactions.

Jan 1, 1998