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Kinetic Leaching Copper
Kinetic Leaching Copper
5277/ppmp140133
Physicochem. Probl. Miner. Process. 50(1), 2013, 399413
Physicochemical Problems
of Mineral Processing
www.minproc.pwr.wroc.pl/journal/
ISSN 1643-1049 (print)
ISSN 2084-4735 (online)
Received August 1, 2013; reviewed; accepted August 29, 2013
LEACHING KINETICS OF COPPER
FROM CHALCOPYRITE CONCENTRATE
IN NITROUS-SULFURIC ACID
Ozge GOK
*
, Corby G. ANDERSON
**
, Gorkem CICEKLI
*
, E. Ilknur COCEN
*
*
Mining Engineering Dept., Faculty of Engineering, Dokuz Eylul University, Izmir, 35160, Turkey;
e-mail: [email protected])
**
Department of Metallurgical and Materials Engineering, Colorado School of Mines, CO, 80401, USA
Abstract: Treating chalcopyrite flotation concentrates by hydrometallurgical techniques seems to be the
most convenient method for leaching copper due to concerns over air pollution and regulations regarding
the emission of sulfur dioxide that result from smelting. In this study, the leaching recovery-time
trajectories of bulk chalcopyrite concentrate obtained from a flotation plant in the Kastamonu region of
Turkey are presented. The effects of various parameters were elucidated in the nitrous-sulfuric acid
electrolyte (C
NaNO2
:0.05 M0.15 M, C
H2SO4
:1 M) at a moderate temperature (80120 C). A high level of
copper recovery (98%) from bulk chalcopyrite concentrate was obtained under a total pressure of 6 atm at
120C within 2 h when using small amounts of nitrite species due to their autocatalytic behavior in acidic
solutions. The kinetics were well correlated with the shrinking core model for the diffusion controlled
mechanism with an apparent activation energy of 34.06 kJmol
1
. Elemental sulfur was the primary
leaching product on the mineral surface, as confirmed using XRD and SEM/EDX. The semi-empirical
equation explaining the reaction rate under the present conditions was expressed as follows:
( )
t
T
e C X X
7 . 4096
83 , 0
0
96 . 0
NaNO
4
3
2
2
10 53 . 56 1
3
2
1
=
.
Keywords: chalcopyrite, pressure leaching, nitrogen species, kinetics
Introduction
Concerns over air pollution and strict environmental regulations regarding the
emission of sulfur dioxide, combined with the increased demand of treating complex
chalcopyrite ores and concentrates with high recoveries, have led to the development
of hydrometallurgical processes as alternatives to smelting. Advances in construction
materials, successful implementation of autoclave technology and development of
O. Gok, C.G. Anderson, G. Cicekli, E.I. Cocen 400
more efficient mills for the fine or ultrafine grinding of sulfides have made
chalcopyrite concentrate leaching more reliable and cost-competitive (Wang, 2005).
In the last two decades, although some hydrometallurgical processes have been
conducted at the lab/pilot scale, only a few have been built at the plant scale (Corrans
and Angove, 1993; Dreisinger et al., 2003; Jones, 1996; Kofluk and Collins, 1998;
Dreisinger et al., 2002; Stanley and Submanian, 1977; Ferron et., 2001; Marsden et al.,
2003). Typically, most of these methods promote the oxidation of copper from
chalcopyrite concentrate in the presence of several species such as ferric ions, ferrous
ions, cupric ions, silver ions, bacteria, pyrite and oxygen (Dixon et al., 2008;
Dreisinger and Abed, 2002; Dutrizac et al., 1969; Hackl et al., 1995; Hirato et al.,
1987; Hiroyoshi et al., 2000; Linge, 1976; Miller and Portillo, 1979; Munoz et al.,
1979).
Sulfuric acid processing with the addition of a small amount of nitrogen species
has been employed for a long time in some industrial applications. The first patented
commercial process by Sunshine Precious Metals (Idaho, USA) used a sulfuric and
dilute nitric acid mixture to leach silver- and copper-bearing ores (Caldon, 1978).
Subsequently, nitric acid leaching was practiced under various process acronyms
such as NSL (Brennecke et al., 1981), NITROX (Van Weert et al., 1986), ARSENO,
and REDOX (Beattie et al., 1989). More recently, a novel process involving nitrogen
species-catalyzed pressure leaching (NSC) was commissioned and performed
successfully on an industrial scale at Sunshine Precious Metals (Anderson et al., 1992;
Anderson et al., 1993). It was reported that silver and copper were successfully
recovered from a complex sulfide concentrate at temperatures between 145C and
155C and at a total pressure of 7 atm (Ackerman et al., 1993). The NSC pretreatment
process was proposed as a potential alternative process capable of being performed at
modest process temperatures and pressures (125-170C and 6-10 atm) and with a
lower oxygen demand (associated with the partial oxidation of sulfide to zero-valence
sulfur). The process employs sulfuric acid to achieve high proton activity, oxygen/air
as the primary oxidant, and a low concentration of nitrite, which, in a broad sense, acts
in a catalytic role (Baldwin and Van Weert, 1996; Anderson, 2003). The reasons for
favoring nitrogen species are (i) they are powerful oxidizing agents, (ii) the NO
x
gases
produced (NO, NO
2
, etc.) remove other reaction products from the mineral surfaces,
(iii) high temperatures increase the reaction rates, and (iv) the oxidant can be
regenerated autocatalytically.
Reaction Sequence of Chalcopyrite Dissolution
The complex chemistry of chalcopyrite leaching in acidic nitrite electrolyte can be
explained based on data (Gok and Anderson, 2013) for the CuFeS
2
-H
2
SO
4
-NaNO
2
-
H
2
O system as follows:
Leaching kinetics of copper from chalcopyrite concentrate in nitrous-sulfuric acid 401
CuFeS
2
+ 8NaNO
2
+ 6H
2
SO
4
= CuSO
4
+ FeSO
4
+ 2NO
2(g)
+ 6NO
(g)
+ 4Na
2
SO
4
+ 2S
o
+ 6H
2
O (1)
2FeSO
4
+ 2NaNO
2
+ 2H
2
SO
4
= Fe
2
(SO
4
)
3
+ Na
2
SO
4
+ 2NO
(aq)
+ 2H
2
O. (2)
In that study, it was found that both nitric oxide (NO
(g)
) and nitrogen dioxide
(NO
2(g)
) were most likely to be generated as products of chalcopyrite leaching with
nitrite. During the oxidation, in addition to NO
(g)
and NO
2(g)
, the system may contain a
number of other nitrogen compounds (HNO
2
, N
2
O
4
, NO
2
-
,
N
2
O
3
, HNO
3
and
NO
3
-
) that
have various catalytic activities. Nitrous acid (HNO
2
) has been predicted to be the
most kinetically reactive form when nitrite salt is introduced into the acidic solution.
The two-step disproportionation reaction mechanism of HNO
2
to NO
(g)
and NO
2(g)
has
been described by Eqs. 3-5 (Park and Lee, 1988).
NaNO
2(aq)
+ H
+
= HNO
2(aq)
+ Na
+
K = 2.51 10
3
(3)
4HNO
2(aq)
= 2N
2
O
3(g)
+ 2H
2
O; K = 4.29 10
3
M
2
atm (4)
2N
2
O
3(g)
= 2NO
(g)
+ 2NO
2(g)
; K = 1.91 atm. (5)
The convincing work by Markovitz et al. (1981) showed that the rate of homolysis
of N
2
O
3(g)
to NO
(g)
and NO
2(g)
was much greater than hydrolysis to HNO
2
. Nitric oxide
is more likely to be in the gas phase due to its lower solubility and is re-oxidized to
HNO
2
in the oxidizing environment (Awad and Stanbury, 1993), as indicated in Eq. 6.
Nitrogen dioxide immediately reacts with water to form two oxyacids, nitric acid and
nitrous acid (Kameoka and Pigford, 1977), according to Eq. 7. The cyclic NO
x
redistribution mechanism is completed by this equilibrium, and only one fourth of the
initial amount of nitrous acid is lost. Finally, all of the nitrogen species that evolve in
the electrolyte from the nitrite salt, except NO
(g)
, are oxidized to nitrate (NO
3
) (Gok,
2009).
2NO
(aq)
+ O
2(aq)
+ H
2
O 2HNO
2(aq)
(6)
2NO
2(g)
+ H
2
O = HNO
3(aq)
+ HNO
2(aq)
; K = 1.81 10
8
M
2
atm
1
. (7)
The reaction scheme explained above takes into account both the steady-state
absorption of NO
x
gases into the electrolyte and the disproportionation reactions.
These non-elementary reaction steps also give a more complete understanding of the
regeneration process.
The present study provides an extensive investigation into the leaching kinetics of
copper from bulk chalcopyrite concentrate in nitrous-sulfuric acid with an emphasis on
the roles of temperature, initial nitrite concentration, and particle size, which have not
been sufficiently studied from a theoretical or practical point of view.
O. Gok, C.G. Anderson, G. Cicekli, E.I. Cocen 402
Material and Methods
Materials
Experiments were implemented with bulk concentrate obtained from the Kre
Copper Concentrator Plant, Eti Bakr A.., Kastamonu-Turkey, where CuFeS
2
ZnS-
FeS
2
complex ore is treated. The chemical and mineralogical compositions of the as-
received bulk concentrate are presented in Table 1.
Mineralogical analyses performed by scanning electron microscopy (SEM) coupled
with energy dispersive spectroscopy (EDS) and X-ray diffraction of the bulk
concentrate revealed that the sample contained mainly chalcopyrite with sphalerite,
pyrite and small amounts of bornite. The primary gangue mineral was quartz.
Chemical analyses by atomic absorption spectrometry (AAS) in conjunction with the
mineralogical findings were used to determine mineralogical composition.
Table 1. Results of the chalcopyrite concentrate head sample assay
Chemical Analysis Mineralogical Analysis
Element % Mineral %
Cu 11.21 CuFeS
2
28
Fe 32.36 Cu
5
FeS
4
3
Zn 5.10 ZnS 8
S 36.8 FeS
2
51
Co 0.06 SiO
2
4
Pb 0.02 CaO 0.35
Ag (g/t) 27
Experimental Procedure
Experiments were conducted using a Parr 1 L 4520 M model vertical reactor
constructed from titanium and controlled to within 2 C using a Parr 4843 model
temperature controller. Typically, the vessel was charged with electrolyte containing
NaNO
2
, H
2
SO
4
and 5% w/v pulp density bulk chalcopyrite concentrate. Sodium nitrite
immediately dissociated to produce nitrous acid in acid solution as described in Eq. 3.
The experiments were initiated by introducing nitrite salt into the electrolyte at
a concentration of 0.050.15 M. The system was then pressurized with oxygen on
a continuous basis to maintain a total pressure of 6 atm. The temperature of the
solution was varied over the range of 80120 C and the reaction sustained for 2 h.
The initial sulfuric acid concentration was 1.0 M and the reaction was mixed well by
stirring at 400 rpm by a magnetically driven twin impeller. Samples from each
experiment were taken at the selected time intervals and analyzed using an atomic
absorption spectrophotometer (Analytik Jena NovaA 300).
XRD and SEM analyses
were performed using a Rigaku Miniflex II diffractometer with Cu K radiation and a
JEOL JXA-733 Superprobe, respectively. The particle size (d
80
) of the received
Leaching kinetics of copper from chalcopyrite concentrate in nitrous-sulfuric acid 403
samples, determined from measurements on an HORIBA/Partica LA-950V2 Particle
Size Analyzer, was 35 m. Ultrafine milling of the as-received material to 15 m was
performed using a ball mill. The size of the product was confirmed by particle size
analysis.
Results and Discussion
Effects of parameters
The influence of the concentration of nitrite on copper recovery was investigated using
an electrolyte containing various initial sodium nitrite concentrations in the range of
0.05 M0.15 M at 120 C. The results are plotted in Fig. 1. Although the recovery-
time curves overlapped during the first 15 min, the reaction rates were enhanced after
the dissociation of nitrite into NO
2(g)
and NO
(g)
in acidic electrolyte. Additionally, the
in situ regeneration of NO
x
during the dissolution process minimized the need to add
additional exogenous nitrite over the course of the reaction.
Fig. 1. Effect of the nitrite concentration on copper recovery. Initial electrolyte conditions:
4 2
SO H
C
=1 M, d
mean
= 15 m, T = 120C, P
tot
= 6 atm
The extraction of copper at various temperatures (80120 C) was implemented in
the electrolyte containing 0.10 M NaNO
2
and 1 M H
2
SO
4
as depicted in Fig. 2. Copper
recovery was enhanced by increasing temperature; 90% extraction was obtained at
120 C, whereas only 60% copper extraction was obtained at 80 C within 2 h. This is
likely due to slower dissolution kinetics as temperature decreases due to the increasing
viscosity of molten sulfur (Papangelakis, 2005).
O. Gok, C.G. Anderson, G. Cicekli, E.I. Cocen 404
Fig. 2. Effect of the temperature on copper recovery. Initial electrolyte conditions:
2
NaNO
C
= 0.10 M,
2 4
H SO
C
= 1 M, d
mean
= 15 m, P
tot
= 6 atm
In this study, a set of grinding tests were performed to determine the effect of
particle size on copper recovery. Tests were performed for three different particle sizes
(35 m, 25 m, and 15 m) at 120 C under a total pressure of 6 atm. The results are
illustrated in Fig. 3. Reducing the material size significantly increased copper recovery
Fig. 3. Effect of the particle size of concentrate on copper recovery. Initial electrolyte conditions:
2
NaNO
C
= 0.10 M,
2 4
H SO
C
= 1 M, T = 120C, P
tot
= 6 atm
Leaching kinetics of copper from chalcopyrite concentrate in nitrous-sulfuric acid 405
(from 70% to 90%). These findings revealed that this is a classic heterogeneous
reaction system in which the larger surface area due to the smaller particle size has a
beneficial effect. Similar behavior has been reported for the nitric-sulfuric acid system
(Anderson et al., 1991). Researchers have explained that this type of dramatic
improvement in conversion is usually indicative of a reaction controlled by diffusional
effects. Less encapsulation of the particle in molten sulfur could be observed by
grinding the material to increase its total surface area. Size reduction also enables
more copper to be solubilized by generating more NO and NO
2
gas according to the
reaction shown in Eq. 1.
Kinetic Analysis
A non-catalytic heterogeneous reaction model was conducted to evaluate the kinetic
parameters and the rate-controlling step of the chalcopyrite dissolution in acidic nitrite
solutions. The rate controlling step of the reaction between solid particles and
electrolyte can be due to one of the following: external diffusion of the reactant
through the boundary layer of the fluid surrounding the particle, reaction on the
surface between the fluid reactant and the solid, or internal diffusion of the reactant
through the reaction products on the particle (Levenspiel, 1972; Mazet, 1992). Three
shrinking core models were tested to better understand the leaching mechanism of
chalcopyrite in acidic nitrite solutions (Aydogan et al., 2005; Levenspiel, 1972):
t
r
C k b
X
o B
A g
'
3
= (film diffusion control) (8)
t
r
C k b
X
o B
A r
'
3
1
) 1 ( 1 = (surface chemical reaction control) (9)
t
r
C D k b
X X
o B
A e d
2
'
3
2
2
) 1 (
3
2
1
=
3
2
) 1 (
3
2
1 (13)
Fig. 8. Dependence of rate constant
on particle size radius
Fig. 9. Determination of constant b
in semi-empirical model equation
The constant a was estimated to be 0.96 from the slope of the line in Fig. 7. The
order of the initial particle radius, b, was found to be 0.83 from the ln k vs. ln
o
plot
in Fig. 9. Substituting the values of a, b, and E
a
into Eq. 13, the value of k
o
is
calculated to be 56.5310
4
. Hence, the proposed model equation to describe
chalcopyrite leaching in acidic nitrite electrolyte is described as follows:
t e C X X
T
o
7 . 4096
83 . 0 96 . 0
NaNO
4
3
2
2
10 53 . 56 ) 1 (
3
2
1
= . (14)
Leaching kinetics of copper from chalcopyrite concentrate in nitrous-sulfuric acid 409
The agreement between experimental results and theoretical calculations (Eq. 13)
was tested (Fig. 10). The correlation is reasonably satisfactory and suggests that Eq.
14 can be used to predict the leaching rate for the ranges of particle size, acid
concentrations and temperatures used in this study.
Fig. 10. Correlation of the observed and estimated values of reaction rate constants
Characterization of Solid Residue
Chemical (AAS) and physical analyses (SEM and XRD) were performed to explain
the behavior of the sulfide concentrate during the leaching of chalcopyrite with nitrite.
Chemical analyses of the solid residue indicated that during the first hour most of the
pyrite and sphalerite were leached. The dissolution of chalcopyrite, pyrite and
sphalerite over time can also be observed from the XRD analyses of the head sample
(Fig. 11a) and residues obtained after 2 h (Fig. 11b). SEM micrographs and X-ray
diffraction spectra revealed non-conductive sulfur layers and quartz to be the major
components. The micrographs and spectra of product layers formed on the particle
surface are presented in Fig. 11 and Fig. 12 for the optimum chalcopyrite dissolution
conditions: 0.10 M NaNO
2
, 1 M H
2
SO
4
at 393 K. As the sulfur layer builds, it impedes
the reaction so that diffusion through the product layer is a major reaction barrier.
However, it is clear that the formation of elemental sulfur does not hinder the reaction
within two hours at higher temperatures.
O. Gok, C.G. Anderson, G. Cicekli, E.I. Cocen 410
Fig. 11. XRD patterns of (a) bulk concentrate, (b)
solid residue at 120 C after 2 h. In the figure:
Ch = chalcopyrite, P = pyrite, Sp = sphalerite,
B = Bornite, S = Sulfur, Q = Quartz
Fig. 12. SEM micrographs of solid residue at 120 C
after 2 h at magnification 1500
Conclusions
The kinetics of dissolution of bulk chalcopyrite concentrate in acidic nitrite
electrolyte have been investigated in the temperature range of 80120 C. On the basis
of the results provided by the experiments, the following can be concluded.
- An increase in nitrite concentration from 0.05 M to 0.15 M caused a significant
increase in leaching from 72% to 98% over the course of 120 min.
- The dissociation products of nitrous acid, NO and NO
2
, were realized during the
withdrawn of the liquid samples. The rapid extraction of copper from the complex
mineral matrix with such small amounts of nitrite revealed that NO reacted with
oxygen to regenerate HNO
2
. Accordingly, nitrous acid could follow a second
reaction path by reacting with a nitrate ion, reducing the nitrate to form NO
2
and
water. The key intermediate product of the reaction, nitrous acid, serves both to
reduce nitrate and to oxidize NO. Overall, more nitrous acid is produced than
consumed.
Leaching kinetics of copper from chalcopyrite concentrate in nitrous-sulfuric acid 411
- The leaching of chalcopyrite concentrate with a particle size of 15 m in nitrite-
containing solutions had a high reaction rate. Over 98% of the copper was
dissolved in 120 min at 120 C. Pyrite and sphalerite were completely dissolved
within 120 min, as confirmed with X-ray diffraction measurements.
- The extraction of copper obeyed a shrinking core model with a diffusion-controlled
mechanism in which the diffusion through the product layer was the rate-limiting
step. The value of activation energy was calculated to be 34.06 kJmol
1
and the
reaction order with respect to nitrite concentration was 0.96. This is consistent with
the following semi-empirical relation:
t e C x X X
T
o
7 . 4096
83 . 0 96 . 0
NaNO
4
3
2
2
10 53 . 56 ) 1 (
3
2
1
= .
- The results of the post-leaching process indicated the presence of a residue
containing elemental sulfur and quartz as its major constituents. This was
confirmed by both X-ray diffraction spectra and SEM micrographs.
Acknowledgement
The author wish to express appreciation to Eti Bakir A.S. for supplying the Kre chalcopyrite
concentrate. Dr. Hatice Yilmaz is also acknowledged for the acquisition of XRD and SEM data.
Appreciation is extended to Dr. Erkan Gler for his invaluable comments.
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Nomenclature
a order of sodium nitrite concentration
A pre-exponential factor (min
1
)
b order of particle diameter
b
l
stoichiometric coefficient
C
A
bulk concentration of the fluid (molm
3
)
C
NaNO2
initial concentration of sodium nitrite
(M)
D
B
effective diffusion coefficient (m
2
s
1
)
E
A
activation energy (kJmol
-1
)
k
d
apparent reaction rate constant (min
1
)
k
g
rate constant of film diffusion
k
0
constant of semi-emprical equation
k
r
rate constant of surface reaction
K equilibrium constant
r
0
radius of unreacted core (mm)
R universal gas constant (J.mol
1
K
1
)
t reaction time (min)
T temperature (K)
X fractional conversion
B
molar density of B in the solid (mol.m
-3
)
0
initial size of solid particle (mm)